Polymer non-aqueous dispension, process for preparing the same and coating composition formulated therewith

ABSTRACT

A process for preparing polymer non-aqueous dispersions to be formulated together with a binder component in coating compositions, which comprises the steps of: (1) emulsion polymerizing a hydroxy group containing α,β-ethylenically unsaturated monomer, a polyfunctional α,β-ethylenically unsaturated monomer and an α,β-ethylenically unsaturated monomer different therefrom by using a water-soluble polymerization initiator, preferably a persulphate, in a soap free system or in the presence of an ester group containing anionic or cationic surfactant; adding an organic solvent, preferably comprising an amphipathic organic solvent, to a resultant polymer aqueous dispersion; and then adding a basic compound catalyst when the anionic surfactant is used or an acidic compound catalyst when the cationic surfactant is used, to thereby hydrolyze completely said surfactant and water-soluble polymerization initiator at a temperature not exceeding 95° C. as in the condition of suspension; (2) adding an acidic or basic compound to said suspension to neutralize said basic or acidic compound catalyst: then after adding dispersion stabilizing resin, further adding an amine salt of organic acid, followed by leaving said suspension to stand to separate into organic and water layers; and isolating the organic layer from the water layer; and (3) removing residual water in the organic layer. The resultant polymer nonaqueous dispersion comprises polymer particles having a total ionic group concentration (I) less than 2×10 -5  mol/g particle, a hexane tolerance (HT) from 5 to 40 exclusive and a degree of swelling in acetone (S) less than 10, and used with a binder component comprising a polyol resin and a curing agent for preparing coating compositions.

This is a division of application Ser. No. 07/384,098, filed July 24, 1989, now U.S. Pat. No. 4,963,601, which in turn is a Continuation of application Ser. No. 07/225,378, filed July 28, 1988, abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to stable polymer non-aqueous dispersions which comprise dispersed particles having nonionic and highly reactive surfaces, and are employable as anti-sag agents of coating compositions and aluminum pigment orientators or binder components of metallic coatings, and to a process for preparing the same and further to coating compositions formulated with the same.

2. Description of the Prior Art

Recently, coatings for automobiles have made a great advance in durability, providing high performances. This advance has been accompanied by increasing demands for higher qualities in aesthetic appearance of the coating films.

To accede to such demands, as for example disclosed in Japanese Patent Application Laid-open No. 53-133,234 (British Patent Specification No. 1,588,976), crosslinked polymer particles (may be hereinafter referred to as "polymer particles" or simply "particles") formed by emulsion polymerization processes or the NAD process have recently drawn particular attention from the fact that the polymer particles, when used in coating compositions, provide the coating compositions with structural viscosity based on interactions between the particles to display excellent flow control functions, such as metallic pigments orientation, sag prevention or the like.

The polymer particles to be used for such purposes are provided in the form of polymer non-aqueous dispersions that can be roughly classified into the following three types. Namely, the first type is, as disclosed in Japanese Patent Applications Laid-open Nos. 58-129,065, 58-129,066, 58-129,069 (U.S. Pat. Nos. 4,530,946 and 4,461,870 are counterparts of these three), 60-250,068 and 61-42,579 (U.S. Pat. No. 4,563,372 is counterpart of these two), those obtained by the steps of: preparing crosslinked polymer particles by emulsion polymerization of α,β-ethylenically unsaturated monomers in the presence of an amphoteric resinous surface active agent; then spray drying the resulting polymer particles to obtain dried particles; and re-dispersing the obtained dried particles in a solvent. This type is mainly used for the purpose of coating thickness increase. The second one is, as disclosed in U.S. Pat. Nos. 4,290,932 (Japanese Patent Application Laid-open No. 56-76,447), 4,377,661, 4,414,357, 4,477,536 and 4,598,111, is crosslinked polymer particles dispersed in a resinous solution which are prepared by the steps of: synthesizing by emulsion polymerization crosslinked polymer particles having ionic groups and polar groups on the surface; then, adding an azeotropic solvent to the resulting emulsion; and 1 after coagulation dehydration and/or azeotropic dehydration, adding the resulting particles into the resin solution, 2 after adding the emulsion to a solution polymerization batch of acrylic resins, conducting polymerization while azeotropically dehydrating or 3 after mixing the emulsion with the resin solution, conducting azeotropic dehydration. The thus obtained particles dispersions have been used mainly for aluminum pigment orientators of metallic coatings by utilizing interparticle hydrogen bonding force and ionic bonding force. Further, the third one is, as disclosed in Japanese Patent Application Publication No. 16,147/1968 and Japanese Patent Applications Laid-open Nos. 53-133,234 and 54-150,439, those obtained through deposition by polymerizing α,β-ethylenically unsaturated monomers in organic solvents in the presence of amphipathic dispersion stabilizers. The obtained particles are used mainly for aluminum pigment orientators of metallic coatings and anti-sag.

However, the polymer non-aqueous dispersions obtained by those three processes have the following difficulties, respectively, and have not yet satisfied high coating performances as well as both qualities and appearances of coating films. Namely, in the polymer non-aqueous dispersions obtained by the processes of the first type, since the resinous surface active agents and fragments of water-soluble polymerization initiators used in the manufacturing processes remain therein, ionic groups remain on surfaces of the particles, which deteriorate water resistance and moisture resistance of coating films or are liable to adsorb onto pigments, causing pigment aggregation when the dispersions are used in coating compositions.

Further, in the polymer non-aqueous dispersions obtained by the processes of the second type, fixation on surface of surface active agents is prone to occur during the emulsion polymerization, due to grafting on particle surfaces of lipophilic groups of the surface active agents, entanglement of molecular chains, or the like and, additionally, fragments of water-soluble polymerization initiators are also fixed on the particle surfaces to provide ionicity. Further, even if the solvent addition and coagulation dehydration process is used that is the most feasible to remove the surface active agents among the processes for dehydrating the emulsions, these oil-soluble emulsifiers are apt to remain in the organic phase. Removal of such surface active agents and fragments of water-soluble polymerization initiators is very difficult. As is referred to in Journal of Colloid and Interface Science, Vol. 52, p. 479 (1979) and U.S. Pat. Nos. 4,461,870 and 4,530,946, it is deemed impossible to remove completely surface active agents used in the emulsion polymerization from surfaces of polymer particles.

Therefore, difficulties are encountered such that, when coating compositions are formulated with the dispersions, water resistance and moisture resistance of coating films are deteriorated and, moreover, since ionic groups are fixed on particle surfaces, pigment aggregation is prone to occur when the dispersions are used in pigment systems, and additionally, they are liable to corrode metallic containers during storage.

Further, in the polymer non-aqueous dispersions obtained by the processes of the third type, since polymer particle forming materials are limited from the synthetic point of view, polar groups are difficult to introduce onto the particle surfaces, so that they are inferior in flow control function based on interactions between the particles to those obtained by the processes of the first and second types. Furthermore, since dispersion stabilizers liable to be solvated with aliphatic solvents are employed, the particles cannot exist with stability in usual coating solvents having a relatively high polarity, so that they have difficulties such that fusion, deposition, swelling, dissolution, etc. of dispersed particles are liable to occur.

SUMMARY OF THE INVENTION

We, the inventors, as a result of assiduous studies of measures to obviate the above difficulties, have accomplished the present invention by obtaining polymer non-aqueous dispersions free from ionic substances and finding that use of these dispersions allows qualities and appearances of coating films to improve without affecting coating performances. The polymer non-aqueous dispersions free from ionic substances are obtained by producing crosslinked polymer particle aqueous dispersions through emulsion polymerization, using ester group containing surface active agents that have a chemical structure containing ester groups of an acid having hydrophilic groups and a hydroxyl compound having lipophilic groups (hereinafter referred to as "surfactants") and further using persulphates as a water-soluble polymerization initiator, and then by deionizing the particle surfaces through treatment under such conditions that all of the surfactants on the particle surfaces, sulphuric acid esters of water-soluble polymerization initiator fragments and free surfactants, but the particles themselves, are hydrolyzed, simultaneously converting the aqueous system to the non-aqueous system. Further, the inventors have found that flow control functions based on hydrogen bonding force of the particles and weatherability of coating films based on reactivity of the particles can be remarkably improved by providing core-shell type particle structures or extending segment chains having terminal hydroxyl groups outward from particles surfaces.

Namely, the process for preparing polymer non-aqueous dispersions according to the present invention is characterized by the steps of:

1 emulsion polymerizing the following components:

(a) a hydroxyl group containing α,β-ethylenically unsaturated monomer,

(b) a polyfunctional α,β-ethylenically unsaturated monomer, and

(c) an α,β-ethylenically unsaturated monomer other than the above (a) and (b),

by using a water-soluble polymerization initiator in a soap-free system or in the presence of an ester group containing surface active agent; adding an organic solvent to a resultant polymer aqueous dispersion; and then adding a basic compound catalyst or an acidic compound catalyst thereto to hydrolyze completely said ester group containing surface active agent and water-soluble polymerization initiator at a temperature not exceeding 95° C. as in the condition of suspension;

2 adding an acidic compound or basic compound to said suspension to neutralize said basic compound catalyst or acidic compound catalyst; then after adding a dispersion stabilizing resin, further adding an amine salt of organic acid, followed by leaving a system of said suspension to stand to separate into two layers, an organic layer and a water layer; after removing the water layer, washing the organic layer by adding water; adding an amine salt of an organic acid, followed by standing to separate; removing the water layer; and

3 removing residual water in the organic layer.

Polymer non-aqueous dispersions prepared by the above-mentioned process of the present invention have a total ionic group concentration (I), a hexane tolerance (HT) and a degree of swelling in acetone (S) which are in an interrelation as defined by the following equations:

    I<2×10.sup.-5 mol/g particle,

    5<HT<50

    and

    S<10.

Coating compositions formulated with the above polymer non-aqueous dispersions comprise 100 parts by weight of a resinous solid matter mixture consisting of 30˜90% by weight of a polyol resin and 10˜70% by weight of a curing agent reactable with hydroxyl group and 1˜50 parts by weight of polymer particles in a polymer non-aqueous dispersion having the above-defined characteristics.

DETAIL DESCRIPTION OF THE INVENTION

In the process for preparing polymer non-aqueous dispersion according to the present invention, the emulsion polymerization may be performed by conventional processes, namely, processes wherein a mixture of α,β-ethylenically unsaturated monomers is added to hot water containing a water-soluble polymerization initiator in a soap-free system or in the presence of a surfactant. However, as a manner of addition of the mixture of α,β-ethylenically unsaturated monomers, gradual addition into the hot water is preferred in order to prevent interparticle crosslinking reactions during the polymerization.

The component (a) in the polymer non-aqueous dispersions to be employed in the process according to the present invention is an α,β-ethylenically unsaturated monomer, such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, glycerol (meth)acrylate or the like. These can be used alone or in combination arbitrarily. However, it is more preferable that the component (a) contains at least 5 mole % of one kind or a mixture of two kinds or more of α,β-ethylenically unsaturated monomers having hydroxyl group terminated segment chains (hereinafter referred to as "an active hydroxyl group type monomer") as shown in the following formulae: ##STR1## wherein R₁ and R₂ represent hydrogen atom or methyl group, and l is an integer of 1˜10, ##STR2## wherein R₃ is hydrogen atom or methyl group, R₄ and R₅ represent ethylene group or isopropylene group and m+n is an integer of 2˜15, and ##STR3## wherein R₆ is hydrogen atom or methyl group, R₇ is an alkylene group having 1˜17 carbon atoms and p is an integer of 1˜10.

Hereupon, since at least 5 mole % of the above active hydroxyl group type monomers contained in the component (a) augment extremely interparticle hydrogen bonding force, the component (a) can exhibit more excellent flow control functions. Additionally, the hydroxyl groups on the particle surfaces highly increase in reactivity to facilitate matrix formation by reacting strongly with curing agents in the coating films, so that weatherability of the formed coating films can be improved. Hereupon, in any case where l in the above formula (1) exceeds 10, m+n in the formula (2) exceeds 15 or p in the formula (3) exceeds 10, the active hydroxyl group type monomers decrease in copolymerizability, becoming hardly incorporated into the particles and so it is not preferable.

The active hydroxyl group type monomers shown in the above formula (1) can be readily manufactured by ring opening addition of 1˜10 moles of ε-caprolactone to 1 mole of 2-hydroxyethyl (meth)acrylate or 2-hydroxypropyl (meth)acrylate. Alternatively, these are commercially available as for example Placcels FM1, FM2, FM3, FM4, FM7 and FM10 (all trade names, manufactured by Daicel Chemical Industries, Ltd.) Hereupon, other than the active hydroxyl group type monomers shown in the formula (1), also employable are monomers manufactured by adding 1˜10 moles of other lactones, such as β-propiolactone, β-butylolactone, γ-butylolactone, pivalolactone, γ-valerolactone, δ-valerolactone or the like, to 1 mole of 2-hydroxyethyl (meth)acrylate or 2-hydroxypropyl (meth)acrylate. Further, the active hydroxyl group type monomers shown in the above formula (2) can be readily manufactured by ring opening addition of 2˜10 moles of ethylene oxide and/or propylene oxide to 1 mole of (meth)acrylic acid. Alternatively, these are commercially available as for example Blemmers PP 1000, PP 500, PP 800, PE 90, PE 200, PE 350 and PEP 350B (all trade names, manufactured by Nippon Oil & Fats Co., Ltd.). Further, the active hydroxyl group type monomers shown in the formula (3) can be readily manufactured by self-condensing 1˜10 moles of a hydroxycarboxylic acid having 2˜18 carbon atoms, such as glycolic acid, lactic acid, 12-hydroxy stearic acid or the like, and then esterifying the condensate compounds with glycidyl (meth)acrylate.

The component (b) of the polymer non-aqueous dispersions to be employed in the process of the present invention is a poly-functional α,β-ethylenically unsaturated monomer that is used for the purpose of firmly three-dimensional crosslinking of polymer particles in order to prevent, when used in coating compositions, swelling in solvent of the polymer fine particles and diffusion into the inside of the particles of hydroxyl groups on surfaces of the polymer particles. As such an α,β-ethylenically unsaturated monomer, mention may be made of, for example:

divinyl benzene,

diallyl phthalate,

diallyl terephthalate,

ethylene glycol di(meth)acrylate,

diethylene glycol di(meth)acrylate,

triethylene glycol di(meth)acrylate,

polyethylene glycol di(meth)acrylate,

1,4-butane diol di(meth)acrylate,

1,3-butylene glycol di(meth)acrylate,

1,6-hexane diol di(meth)acrylate,

neopentyl glycol di(meth)acrylate,

2-hydroxy-1,3-di(meth)acryloxy propane,

2,2-bis[4-(meth)acryloxyethoxy)phenyl]propane,

trimethylol propane tri(meth)acrylate,

tetramethylol methane tri(meth)acrylate,

pentaerythritol tri(meth)acrylate,

dipentaerythritol tri(meth)acrylate,

pentaerythritol tetra(meth)acrylate,

dipentaerythritol penta(meth)acrylate,

dipentaerythritol hexa(meth)acrylate,

tetramethylol methane tetra(meth)acrylate,

epoxy prepolymers,

urethane (meth)acrylates,

or the like. These may be used alone or in combination.

The component (c) of the polymer non-aqueous dispersions to be employed in the process of the present invention is a hydroxyl-free, nonionic α,β-ethylenically unsaturated monomer for forming the polymer particles that is different from the components (a) and (b). The component (c) may be used arbitrarily according to properties of the coating compositions to be formulated therewith, such as compatibility, refractive index, polarity or the like. However, if the component (c) is so selected, preferably as a known technique teaches (in "ABS Resin" p. 53, (1970), edited by Japan High Polymer Society, published by Maruzen Co.), that the difference in refractive index between the binder in the coating compositions and the polymer particles may be adjusted to be 0.005 or less, appearances and qualities of coating films can be improved. As such an α,β-ethylenically unsaturated monomer other than the components (a) and (b), mention may be made of, for example;

methyl (meth)acrylate,

ethyl (meth)acrylate,

n-propyl (meth)acrylate,

isopropyl (meth)acrylate,

n-butyl (meth)acrylate,

isobutyl (meth)acrylate,

t-butyl (meth)acrylate,

n-hexyl (meth)acrylate,

cyclohexyl (meth)acrylate,

2-ethylhexyl (meth)acrylate,

lauryl (meth)acrylate,

(meth)acrylamide,

(meth)acrylonitrile,

vinyl acetate,

vinyl propionate,

vinyl butyrate,

vinyl caproate,

vinyl 2-ethylhexanoate,

vinyl laurate,

vinyl stearate,

styrene,

α-methylstyrene,

vinyl toluene,

vinyl chloride,

vinylidene chloride,

dibutyl fumarate,

or the like. These may be used alone or in combination.

Further, the polymer non-aqueous dispersions according to the present invention which have a core-shell type particle structure can display further increased flow control functions and weatherability improving effects based on matrix formation of the particles by reaction with curing agents in the coating films. Such core-shell type particles can be obtained by effecting emulsion polymerization of 5 weight % or more of a mixture of the components (b) and (c) on the outset, and then subsequent core-shell type emulsion polymerization of the remainder of the components (b) and (c) mixture with the component (a). Hereupon, when the mixture of the components (b) and (c) at the first stage of the emulsion polymerization is in an amount of less than 5% by weight based on the total amount of the mixture, the abovementioned further increased flow control functions and weatherability improving effects will not be able to be expected.

In the emulsion polymerization, there are generally many cases where a water-soluble polymerization initiator is used. Such a water-soluble polymerization initiator, after radical fission, is deposited on the polymer particle surfaces, directing hydrophilic groups in the water-soluble polymerization initiator towards aqueous medium. Since the hydrophilic groups of the water-soluble polymerization initiator are generally ionic groups, when the polymer particles are formed by emulsion polymerization, ionic groups are introduced onto the polymer particle surfaces. Accordingly, in the polymer non-aqueous dispersions according to the process of the present invention, after the emulsion polymerization, the above water-soluble polymerization initiator fragments are subjected to a hydrolysis treatment to scission-remove the ionic groups from the particle surfaces in order to deionize the polymer particle surfaces. As such a water-soluble polymerization initiator of which ionic groups can be scission-removed from the particle surfaces by a hydrolysis treatment, particularly preferable are, for example, persulphates, such as sodium persulphate, potassium persulphate, ammonium persulphate or the like. These may be used alone or in combination. Needless to say, in this case, ferrous salts, acid sodium sulphite, N,N-dimethyl aniline or the like can be used in combination with the persulphates, as a redox polymerization initiating system.

Hereupon, the water-soluble polymerization initiators are used, in the case of a soap-free system, in an amount of 1˜10% by weight of total α,β-ethylenically unsaturated monomers, and in the presence of surfactants, in an amount ranging 0.1˜2% by weight. In the case of the soap-free system, if the water-soluble polymerization initiators are in an amount of less than 1% by weight, the polymer particles will aggregate due to poor emulsification, while in excess of 10% by weight, the polymer particles will also aggregate by salting-out, so that either case is not preferable. In the presence of surfactants, if less than 0.1% by weight, polymerization conversion will become so low that polymer particles are hardly produced, while in excess of 2% by weight, the polymer particles will aggregate by salting-out, so that either case is not preferable.

Further, the emulsion polymerization is performable both in a soap-free system and in the presence of surfactants. In the latter case, fixation on surface of active agents is prone to occur due to grafting on particle surfaces of lipophilic groups of the surfactants, entanglement of molecular chains, or the like, and the particle surfaces are ionized. Accordingly, in the polymer non-aqueous dispersions according to the present invention, in the case of the presence of surfactants, after the emulsion polymerization, the surfactants fixed on the surfaces are subjected to a hydrolysis treatment to scission-remove the ionic groups from the particle surfaces in order to deionize the polymer particle surfaces. As such a surfactant that can be scission-removed by hydrolysis treatments, particularly preferable are ester group containing surfactants. As an anionic surfactant, mention may be made of, for example, alkyl sulphates, monoalkyl sulfosuccinates, dialkyl sulfosuccinates, alkylether sulphates, polyoxyethylene alkylphenylether sulphates, alkyl phosphates, alkylether phosphates, and Na-salts, K-salts or amine salts of sulphonic acid compounds represented by the following formula: ##STR4## wherein R₁₀ is alkyl group having 12˜18 carbon atoms. Those may be used alone or in combination. Additionally, the alkyl sulphates include, for example, sodium lauryl sulphate, sodium 2-ethylhexyl sulphate, or the like; the monoalkyl sulfosuccinates include, for example, sodium hexyl sulfosuccinate or the like; the dialkyl sulfosuccinates include, for example, sodium dihexyl sulfosuccinate, sodium di-2-ethylhexyl sulfosuccinate or the like; the alkylether sulphates include, for example, sodium polyoxyethylene laurylether sulphate or the like; the polyoxyethylene alkylphenylether sulphates include, for example, sodium polyoxyethylene octylphenylether sulphate or the like; the alkyl phosphates include, for example, potassium lauryl phosphate or the like; and the alkylether phosphates include, for example, potassium polyoxyethylene lauryl phosphate or the like. These may be used alone or in combination.

Further, as a cationic surfactant, mention maybe made of, for example, compounds represented by the following formula: ##STR5## wherein R₁₁ is alkyl group having 12˜18 carbon atoms. When the emulsion polymerization is conducted, it is preferred that the above surfactants is used in an amount yielding the concentration in water of 7% or less by weight. Hereupon, in the case where the concentration of the surfactants exceeds 7% by weight, ionic compounds produced by hydrolysis of the surfactants are liable to remain in the polymer non-aqueous dispersion to deteriorate water resistance of coating films, so that it is not preferable.

By such an emulsion polymerization, polymer particles having an average particle diameter of 10˜5,000 nm can be obtained.

The polymer non-aqueous dispersions according to the present invention can be manufactured by subjecting the polymer particles thus formed by the emulsion polymerization process to the subsequent process to convert to a non-aqueous system.

Namely, on the outset, an organic solvent that causes neither dissolution nor aggregation of particles nor water separation is added to the polymer aqueous dispersions produced by the emulsion polymerization. Such an organic solvent desirably contains 20˜100% by weight of an amphipathic organic solvent that is compatible with hydroxyl groups on particle surfaces. As such an amphipathic organic solvent, suitable are alcohols, ketones, ethers, glycol ethers, or the like, which can form hydrogen-bonds with hydroxyl groups on the particle surfaces to prevent interparticle aggregation. Hereupon, if the amphipathic organic solvent is in an amount of less than 20% by weight, the interparticle aggregation and water separation will occur so that it is no preferable.

As such an amphipathic organic solvent compatible with hydroxyl groups on particle surfaces, mention may be made of, for example, alcohols such as 2-ethyl-1-butyl alcohol, 3-heptyl alcohol, 1-octyl alcohol, 2-octyl alcohol, 2-ethylhexyl alcohol, 1-nonyl alcohol, 3,5,5-trimethyl-1-hexyl alcohol, 1-decyl alcohol, 1-undecryl alcohol, 1-dodecyl alcohol, n-butyl alcohol, n-pentyl alcohol, n-hexyl alcohol, secondary butyl alcohol, isobutyl alcohol, 2-pentyl alcohol, 4-methyl-2-pentyl alcohol, 3-pentyl alcohol, 2-methyl-1-butyl alcohol, or the like; ketones such as methyl-n-propyl ketone, methyl-isopropyl ketone, diethyl ketone, methyl-n-butyl ketone, methyl-isobutyl ketone, methyl-n-pentyl ketone, di-n-propyl ketone, di-isobutyl ketone, ethyl-n-butyl ketone, methylethyl ketone, or the like; ethers such as diethyl ether, dipropyl ether, di-isopropyl ether, dibutyl ether, dihexyl ether, dioxane, tetrahydrofuran, tetrahydropyran, 1,2-diethyloxy ethane, or the like; and glycol ethers such as 2-isopentyloxy ethanol, 2-hexyloxy ethanol, 2-phenoxy ethanol, or the like. These may be used alone or in combination.

Alternatively, organic solvents other than the above, namely, non-amphipathic organic solvents incompatible with hydroxyl groups on particle surfaces, are used in an amount of 0˜80% by weight for the purpose of facilitating a process for removing residual water after conversion of particles to a non-aqueous system. Those are admixed to the aforementioned organic solvents until the solubility of water at 20° C. becomes preferably 5% or less, by weight. As such an organic solvent, mention may be made of, for example, aliphatic solvents such as n-pentane, n-hexane, n-heptane, cyclohexane, methyl cyclohexane, ethyl cyclohexane, or the like; aromatic solvents such as benzene, toluene, xylene, ethyl benzene, or the like; and esteric solvents such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, isobutyl acetate, secondary butyl acetate, or the like.

These can be used alone or in combination and are not limited to the above in the present invention.

Further, the polymer aqueous dispersions are admixed to the organic solvents in an amount ranging 5˜90%, preferably 10˜70% by weight of the total amount of the polymer aqueous dispersion and organic solvent. Hereupon, if the organic solvents are in an amount of less than 5% by weight, the polymer particles will aggregate to raise so high a viscosity of the system that stirring will become hardly performed efficiently, so that it is not preferable. Alternatively, if the amount is in excess of 90% by weight, a water layer will be separated from an organic layer whereby the hydrolysis reaction on the polymer particle surfaces will not proceed sufficiently, causing pigment aggregation in coating compositions and deterioration of water resistance, weatherability, etc. of coating films, so that it is not preferable.

After addition of the organic solvents to the polymer aqueous dispersions, a hydrolyzing process is then conducted. The hydrolyzing process aims to scission-remove ionic groups from particle surfaces to deionize the particles and then transfer completely these particles to the organic layer without aggregating. The hydrolysis reaction is performed at a temperature of not exceeding 95° C., preferably, 70°˜95° C., in the presence of a basic compound catalyst when an anionic surfactant is used, an acidic compound catalyst when a cationic surfactant is used, or a basic or acidic compound catalyst in the case of a soap-free emulsion polymerization. Hereupon, if the reaction temperature exceeds 95° C., not only ionic groups on particle surfaces but also other ester group portions will be hydrolyzed to form carboxyl groups whereby the particle surfaces are ionized, so that it is not preferable. Alternatively, if the reaction temperature is lower than 70° C., it will take a long time to complete the hydrolysis reaction, so that it is not preferable.

Further, the basic compound catalysts or acidic compound catalysts are added in an amount of desirably 1˜3 times the stoichiometric amount of ester groups to be hydrolyzed. If the amount is less than the stoichiometric, a degree of hydrolysis will become so low that ionic groups will be liable to remain on the particle surfaces, so that it is not preferable. Alternatively, if the amount exceeds 3 times, hydrolysis of (meth)acrylates constituting the particles will be commenced, producing carboxyl groups on the particle surfaces, so that it is not preferable. Hereupon, the "stoichiometric amount of ester groups to be hydrolyzed" is to be meant by the sum total of double amount of persulphates and total amount of ester groups of surfactants.

By performing the hydrolysis reaction under such conditions, the total ionic group concentration of the polymer particles can be made to be 2×10⁻⁵ mol/g particle or less. Hereupon, as a basic compound catalyst, mention may be made of, for example, sodium hydroxide, potassium hydroxide, lithium hydroxide, tetramethyl ammonium hydroxide, tetraethyl ammonium hydroxide or the like, and as an acidic compound catalyst, for example, sulphuric acid, hydrochloric acid, p-toluene sulphonic acid, methane sulphonic acid, benzene sulphonic acid or the like. A progress degree of hydrolysis can be followed by neutralization titration, etc. of consumption of the basic compound catalyst or acidic compound catalyst added and the end-point of titration can be found easily.

After completion of the hydrolysis reaction, a neutralization reaction is conducted according to the conventional method, with an acidic compound same as the aforementioned acidic compound catalysts in the case of a system wherein the basic compound catalyst has been used, and with a basic compound same as the aforementioned basic compound catalysts in the case where the acidic compound catalyst has been used, and thereafter 20˜200 parts by weight, as resinous solid matter, of a dispersion stabilizing resin are added to 100 parts by weight of the polymer particles to stabilize the particle dispersion. The dispersion stabilizing resin to be used herein is preferred to have compatibility with binders of coating films. As such a dispersion stabilizing resin, any one or mixtures of acrylic resins, alkyd resins and polyester resins having essentially hydroxyl groups, or any one or mixtures of amino resins such as melamine resins, benzoguanamine resins, urea resins, glycoluryl resins and the like, are preferred.

Additionally, if the dispersion stabilizing resin is in an amount as resinous solid matter of less than 20 parts by weight based on 100 parts by weight of the particles, there may be the case where the dispersion stability of the particles is so much decreased that the particles coalesce at gas-liquid interfaces, etc. in the reactor. Alternatively, if in excess of 200 parts by weight, efficiency of separation into two layers consisting of an organic layer containing the polymer particles and a water layer will be lowered, so that it is not preferable.

After addition of the dispersion stabilizing resin, an amine salt of organic acid is further added to the system and then stirring is stopped, followed by leaving the system to stand to separate into two layers: a resinous solution layer (organic layer) containing the particles and a water layer containing ionic substances. The ionic substances mentioned here include hydrolysis reaction products of surfactants and water-soluble polymerization initiator fragments; basic compound catalysts and acidic compound catalysts added in the hydrolysis reaction and neutralization reaction; or salts produced in the neutralization reaction. Hereupon, it is preferred to warm up the system with the intention of furtherance of water separation, and by maintaining the temperature of the system in the range between 50° C. and 80° C., water separation efficiency can be raised.

The organic acids to be used in the amine salt of organic acid to be added here include, for example, carboxylic acids such as formic acid, acetic acid, propionic acid, oxalic acid, malonic acid or the like; sulphonic acids such as methane sulphonic acid, ethane sulphonic acid or the like; and organophosphoric acids such as monomethyl phosphoric acid, monoethyl phosphoric acid, dimethyl phosphoric acid, diethyl phosphoric acid or the like. Alternatively, as the amines, those having a boiling point of 150° C. or less are particularly preferred, and mention may be made of, for example, primary amines such as monoethylamine, propylamine, isopropylamine, n-butylamine, isobutylamine, secondary butylamine, t-butylamine, pentylamine or the like; secondary amines such as dimethylamine, diethylamine, dipropylamine, diisopropylamine, diisobutylamine, dipentylamine or the like; and tertiary amines such as trimethylamine, triethylamine, tripropylamine, tributylamine, pyridine or the like. However, the organic acids and amines to be employed in the present invention are not specifically limited to the above. Hereupon, if amines having a boiling point of higher than 150° C. are used, there may be the case where the amines remain in polymer non-aqueous dispersions to deteriorate properties of coating films, such as water resistance, etc.

The amine salts of organic acid consisting of a combination of the above organic acid and amine can be readily manufactured by mixing predetermined amounts of the organic acid and amine in the presence of water at normal temperatures. Further, it is appropriate that the amine salts of organic acid are added in an amount ranging 0.1˜10%, preferably 1˜5%, by weight, based on the water existing in the system. If it is less than 0.1% by weight, the efficiency of separation into water layer and organic layer will be lowered, while if in excess of 10% by weight, the amine salts of organic acid are liable to remain in polymer non-aqueous dispersions, thereby deteriorating properties of coating films, such as water resistance, etc. so that either case is not preferable.

Next, after removing the water layer, ionic substances remaining in the organic layer is washed off with water and then after the above amine salt of organic acid is added, the organic layer is left to stand to separate and remove the washing water. The water-washing process is repeated until pH of the separating and removing water layer reaches 5˜8 and ionic substances remaining in the organic layer decrease to 50 ppm or less. Hereupon, if the pH of the water layer to be separated and removed is lower than 5 or exceeds 8, or the ionic substances remaining in the organic layer exceed 50 ppm, the properties of coating films, such as water resistance or the like, will be deteriorated, so that either case is not preferable.

Further, if the residual water is reduced to 5% by weight in the organic layer after washing with water, removal of the residual water in the subsequent process can be facilitated.

The residual water in the organic layer can be removed by the following methods:

(a) distillation of the water under vacuum,

(b) removal by decomposition through reactions with compounds,

(c) water-absorbing treatment with a water-absorbent, or

(d) removal of water by azeotropy or spray drying.

The method (a) is a method wherein only water is distilled out at 50°˜100° C. under a reduced pressure of less than 760 mmHg, as the system is not forming azeotropic mixture with water. The method (b) is a method wherein orthocarboxylic acid esters, such as methyl orthoformate, ethyl orthoformate, methyl orthoacetate, ethyl orthoacetate or the like, or diketene, formamide, dicyclohexyl carbodiimide or the like is added and the residual water is decomposed by reacting therewith at 30°˜90° C. If the reaction temperature is lower than 30° C., the water decomposition will require a long time, while if in excess of 90° C., moisture will condense at vacant spaces in the reactor, rather resulting in insufficient water-removal, so that either case is not preferable. In this water removing method, low boiling point solvents are by-produced as decomposition products, such as methyl alcohol, ethyl alcohol, methyl formate, ethyl formate, methyl acetate, ethyl acetate or the like, when the orthocarboxylic acid esters are used, or such as acetone or the like, when the diketene is used. Therefore, it is preferred that these low boiling point solvents are distilled off under vacuum, after the water decomposition reaction, for the purpose of preventing popping of coating films. Further, ammonium formate when the formamide is used, or dicyclohexyl urea when dicyclohexyl carbodiimide is used, is by-produced, such a decomposition product is required to be separated by filtration after the water decomposition reaction. The method (c) is a method wherein the organic layer is passed through a column filled with polymer water absorbents, such as Sumika Gel S-50, SP-520, N-100, Np-1020, F-03, F-03, F-51 or F-75 (all trade names, manufactured by Sumitomo Chemical Co., Ltd.), Aquakeep 4S or 10HS (both trade names, manufactured by Seitetsu Kagaku Co., Ltd.) or molecular sieves, or a method wherein any one of or a mixture of the above polymer water absorbents, molecular sieves or dehydrates of inorganic salts such as sodium sulphate, calcium chloride, calcium oxide or the like is admixed with the organic layer and, after stirring, separated by filtration. The method (d) is a water removing method that has been generally used to obtain dry particles after emulsion polymerization, as is for example referred to British Patent No. 967,051, page 5, wherein organic solvents capable to form an azeotropic mixture with water are added and water is azeotropically distilled off at 50°˜100° C. Alternatively, it is a method wherein the organic layer is sprayed at 20°˜100° C. from a nozzle to vaporize water with organic solvent and then drying residue is dispersed again in the organic solvent.

The method (b) among the other water removing methods is characterized by a simple process having an extremely high degree of dehydration. This method allows nearly all of adsorbed water to remove, whereas according to the other water removing methods water adsorbed and coordinated on particle surfaces are hardly removed.

Meanwhile, the polymer particles are preferably contained in polymer non-aqueous dispersions in an amount ranging 2˜50% by weight. If it is less than 2% by weight, the flow control function becomes so deficient that improvements in appearance and quality of coating films cannot be attained, so that it is not preferable.

If it exceeds 50% by weight, the polymer non-aqueous dispersions become so high viscous during manufacture that aggregates of the polymer particles are prone to be formed and when coating compositions are formulated therewith the polymer particles are apt to aggregate as well, so that it is not preferable.

The thus obtained polymer non-aqueous dispersions are desirably designed to have a total ionic group concentration (I) of polymer particles in the polymer non-aqueous dispersions, a hexane tolerance (HT) and a degree of swelling in acetone (S) which are in ranges satisfying the following relations, respectively:

    I<2×10.sup.-5 mol/g particle;                        (4)

    5<HT<40                                                    (5)

    S<10                                                       (6)

The total ionic group concentration of polymer particles can be determined according to the following method. Namely, the obtained polymer non-aqueous dispersion is diluted with a mixed solvent of acetone/water=9/1 (by weight) so that non-volatile matter may become in an amount of 10% by weight. This diluted dispersion is passed through a column filled with ion-exchange resins to ion-exchange all of surfactants and water-soluble polymerization initiator fragments remaining in the dispersion and then a total ionic group concentration of dispersion is quantitatively determined by potentiometric titration. Then, with respect to dispersion stabilizing resins used in the manufacture of the polymer non-aqueous dispersion, an ionic group concentration is determined by potentiometric titration. The total ionic group concentration of polymer particles can be calculated by subtracting the ionic group concentration corresponding to the dispersion stabilizing resins from the total ionic group concentration of dispersion obtained by the above procedures.

The total ionic group concentration in the relation shown by the inequality (4) can be attained, as described in the above manufacturing process, by scission-removing by hydrolysis of surfactants and water-soluble polymerization initiator fragments deposited on polymer particle surfaces under such conditions that polymer particles themselves are not hydrolyzed, to thereby ionize particle surfaces. Hereupon, if the total ionic group concentration of polymer particle is 2×10⁻⁵ mol/g particle or more, the polymer particles and pigments will aggregate due to electric attraction force to deteriorate appearances of coating films as well as to increase hydrophilicity of the polymer particle surfaces to deteriorate water resistance of coating films, so that it is not preferable.

The hexane tolerance of polymer particles can be determined according to the following method. Namely, to the polymer aqueous dispersion obtained by emulsion polymerization, ethyl acetate is added in an amount of 19 times polymer particles, by weight, and after stirring, KBr is further added to separate by salt-out the system into two layers. The separated water layer is then removed. After adding mirabilite to ethyl acetate layer to effect residual water absorbing treatment, the mirabilite is separated by filtration to obtain an ethyl acetate layer wherein polymer particles having non-volatile matter of 5% by weight are dispersed. To 20 parts by weight of this ethyl acetate layer, n-hexane is added until the polymer particles aggregate resulting in a whitish tinted system. The amount of the n-hexane added to 1 part by weight of the polymer particles in the above case is denoted as a hexane tolerance (HT).

The HT of polymer particles has a close relation with polarity of polymer particle surfaces, and the lower the HT, the higher the polarity. The HT can satisfy the relation defined by the inequality(5) by adjusting, in the above manufacturing process, the component (a) (contents of hydroxyl group containing α,β-ethylenically unsaturated monomers and active hydroxyl group type monomers) and particle structures (homogeneous particles or core-shell type particles) so that in the case of the homogeneous particles, the component (a) may be in the range of 1˜50% by weight of the sum total of the components (a), (b) and (c) or in the case of the core-shell type particles, in the range of 1˜50% by weight of the sum total of the components (a), (b) and (c) in the shell component. Hereupon, if the HT is 40 or more, the polarity of the polymer particle surfaces is so low that an expected degree of flow control functions based on interparticle hydrogen bonding force will not be obtained and the reactivity of particle surfaces with curing agents also will be decreased resulting in insufficient matrix formation in coating films of the polymer particles, so that it is not preferable. Alternatively, if the HT is 5 or less, the polarity of the polymer particle surfaces is so high that compatibility with binders will become insufficient and there may be the case of rather deteriorating appearances of coating films.

The degree of swelling in acetone of polymer particles can be determined based on the method described in a known literature, Journal of Coating Technology, p. 33, vol. 52, No. 669, October (1980). Namely, the polymer aqueous dispersion obtained by emulsion polymerization is dropped and dispersed in acetone so that the polymer particle concentration may be 4 g/l, and the degree of swelling in acetone of polymer particles is found by substituting the viscosity of the dispersion measured in the following equation: ##EQU1## wherein, ρ_(p) : density of polymer particles in dry condition,

η_(s) : viscosity of dispersion in acetone,

η_(o) : viscosity of solvent portion of dispersion in acetone, and

m: weight of solid matter of polymer particles in 1 cm³ of dispersion in acetone.

The degree of swelling in acetone (S) of polymer particles has a close relation with the degree of cross-linking of the polymer particles, and the lower the S, the higher the degree of cross-linking. The S can satisfy the relation defined by the inequality (6) by adjusting, in the above manufacturing process, the content of the component (b) to be in the range of 2˜80%, preferably 5˜50%, by weight, based on the sum total of the components (a), (b) and (c) in either case of homogeneous particles and core-shell type particles. By making the S of polymer particles less than 10 by using 2˜80% by weight of the component (b), the range of selection of solvent is very much widened when the system is converted to the non-aqueous system in the above manufacturing process or when formulation of coating compounds so that the degree of freedom of workability in the manufacture of coating compositions. Hereupon, if the S is 10 or more, at the step beginning with the addition of an organic solvent in the above manufacturing process, the viscosity of the system will increase so high that the hydrolysis treatment requires a long time and scales become apt to deposit on walls of the treating bath, so that it is not preferable.

The polymer particles having the above characteristics are used in an amount ranging 1˜50 parts, preferably 3˜30 parts, by weight, based on 100 parts by weight of resinous solid matter of binder in coating composition. Hereupon, if the polymer particles are in an amount of less than 1 part by weight, the flow control functions will become so deficient that improvements in appearance and quality of coating films cannot be attained, so that it is not preferable. Alternatively, if in excess of 50 parts by weight, the flow control functions will be so much augmented inversely that there may be the case of impairing smoothness of coating film surfaces, so that it is not preferable.

The binder components of coating compositions according to the present invention are composed of 30˜90% by weight of a polyol resin and 10˜70% by weight of a curing agent to react with hydroxyl groups. Hereupon, if the polyol resin is in an amount of less than 30% by weight, chemical resistance of the formed coating films will be deteriorated, while in excess of 90% by weight, water resistance of the formed coating films will be also deteriorated, so that either case is not preferable. As a polyol resin, particularly preferable are acrylic resins, alkyd resins or polyester resins. These may be used alone or in combination.

Additionally, as a curing agent to react with hydroxyl groups, mention may be made of amino resins such as melamine resins, benzoguanamine resins, urea resins, glycoluryl resins and the like, or isocyanate compounds. These may be used alone or in combination.

In order to formulate coating compositions according to the present invention, use may be made of conventional apparatuses to be generally used in the manufacture of coating compositions, such as dissolvers, ball mills, paint shakers, sand mills, attritors, roll mills, kneaders or the like. Then, if required, coloring agents such as pigments, dyes, glass flakes, aluminum flakes or the like, and also other additives usually employed in coating compositions, such as pigment dispersants, viscosity modifiers, leveling agents, curing catalysts, anti-gelling agents, UV absorbers, radical scavengers, or the like, may be added.

The coating compositions obtained according to the above process are applied by a usual coating method, such as air spray coating, airless spray coating, electrostatic coating, dip coating or the like, on usual objects to be coated, for example, inorganic materials such as metal or the like, or organic materials such as plastics or the like, and then dried at 60°˜180° C. for 20˜60 minutes, whereby excellent coating films are obtained.

In the polymer non-aqueous dispersions according to the present invention, surfactants and water-soluble polymerization initiator fragments used in emulsion polymerization thereof have been scission-removed by hydrolysis treatment from polymer particle surfaces and cleared from the system, so that these polymer particles surfaces have been turned to non-ionic. Therefore, the coating compositions of the present invention, different from those comprising conventional polymer non-aqueous dispersions, can obviate entirely defects of coating films such as pigment aggregation based on surface charge of particles, deterioration of water resistance and weatherability based on content of hydrophilic substances, or the like.

Furthermore, when the particles are formed into a core-shell type structure and/or a structure having hydroxyl group terminated segment chains extending outward from the particle surfaces, hydroxyl groups on particle surfaces increase in hydrogen bonding force and reactivity with curing agents, so that they can display further augmented flow control functions (functions for controlling metallic pigment orientation and anti-sagging) and weatherability improving effects based on matrix formation of these particles in coating compositions. Accordingly, the coating compositions according to the present invention are remarkably improved in appearance, quality and weatherability of coating films, as compared with those wherein conventional polymer non-aqueous dispersions are employed.

The present invention will be further explained in more detail by way of example and comparative example hereinafter. In examples, parts and percentages are by weight, unless otherwise specified.

1-A. MANUFACTURE OF POLYMER AQUEOUS DISPERSION (IN THE PRESENCE OF SURFACTANTS) Manufacturing Example A1

    ______________________________________                                         Surfactant aqueous solution                                                    Deionized water            380 parts                                           Rapisol B90 (Note 1)       7.4 parts                                           Polymerization initiator aqueous solution 1                                    Deionized water            10 parts                                            Sodium persulphate         0.25 parts                                          Particle-forming α,β-ethylenically unsaturated                      monomer mixture                                                                2-Hydroxyethyl methacrylate                                                                               1.2 parts                                           Ethylene glycol dimethacrylate                                                                            3 parts                                             Styrene                    15 parts                                            n-Butyl methacrylate       80.8 parts                                          Polymerization initiator aqueous solution 2                                    Deionized water            10 parts                                            Sodium persulphate         0.25 parts                                          ______________________________________                                          Note (1)                                                                       Rapisol B90: trade name of sodium di2-ethylhexyl sulphosuccinate,              manufactured by Nippon Oil & Fats Co., Ltd.; active ingredient, 90%.     

A flask equipped with a stirrer, a reflux condenser, a couple of dropping funnels, a nitrogen introducing tube and a thermometer, was charged with surfactant aqueous solution and after raising the temperature to 80° C. under nitrogen stream, polymerization initiator aqueous solution 1 was added. After the temperature had resumed 80° C., as the temperature of the mixture in the flask was kept at 80°±2° C., the particle-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 3 hours. From 1 hour after the commencement of the addition and parallel with the addition of this monomer mixture, the polymerization initiator aqueous solution 2 was also added dropwise taking 2 hours. After completion of the addition of the particle-forming α,β-ethylenically unsaturated monomers and polymerization initiator aqueous solution 2, polymerization was further performed at 80° C. for 2 hours to provide polymer aqueous dispersion A1. With respect to the obtained polymer aqueous dispersion, determined values of non-volatile matter, viscosities measured with Brookfield type viscometer at 20° C. and 60 rpm, and average particle diameters measured with "AUTOSIZER" (trade name) manufactured by Malvern, are shown in Table 1.

(i) Determination of Hexane Tolerance

One hundred parts of the polymer aqueous dispersion A1 and 380 parts of ethyl acetate were added to a beaker and stirred. Then, the mixture was transferred to a separatory funnel and 10 parts of 20% KBr aqueous solution were added thereto to salt-out and separate into two layers. The separated water layer was removed. The ethyl acetate layer was transferred to an Erlenmeyer flask, admixed with mirabilite and left to stand overnight to effect water-absorbing treatment of residual water. Then, the mirabilite was separated by filtration to provide a highly transparent ethyl acetate layer wherein polymer particles having 5% non-volatile matter are dispersed. Twenty parts of this ethyl acetate layer were put in an Erlenmeyer flask and while stirring with a stirrer, n-hexane was added slowly with a burette. At the time when 38 parts of n-hexane had been added to 1 part of polymer particles, the system became cloudy. This amount of the n-hexane added was to represent "Hexane Tolerance".

(ii) Determination of Degree of Swelling in Acetone

Two parts of the polymer aqueous dispersion A1 were added to 98 ml of acetone and dispersed therein. This dispersion in acetone was measured with a Lipkin-Davison type pycnometer for the density (ρ_(s)) at 20° C. and with Cannon-Fenske viscometer for the kinematic viscosity (ν_(s)) at 20° C.

ρ_(s) =0.8055 g/ml

ν_(s) =0.4860 cst

Using these ρ_(s) and ν_(s), the viscosity of the dispersion in acetone (η_(s)) was found from the following equation:

    η.sub.s =ρ.sub.s ·ν.sub.s =0.3915 cps

Further, about 12 parts of the dispersion in acetone were weighed accurately, and after air-dried on a petri dish at 20° C. for 1 day, further dried at 50° C. for 3 hours under a vacuum of 0.2 mmHg. Then, by measuring the solid material weight, the weight of the solid matter per 1 g of the dispersion in acetone (W_(s)) was found.

W_(s) =0.0052

Alternatively, about 12 parts of the dispersion in acetone were weighed accurately, centrifugalized at 15,000 rpm for 1 hour. The density (ρ_(o)), kinematic viscosity (ν_(o)) and weight of solid matter per 1 g of dispersion in acetone (W_(o)), of the solvent portion were determined in the same manner as the above.

    ρ.sub.o =0.7942 g/ml

    ν.sub.o =0.4586 cst

    η.sub.o =ρ.sub.o ·ν.sub.o =0.3642 cps

    W.sub.o =0.0008 g

Using the obtained ρ_(s), W_(s) and W_(o), the weight of the solid matter of polymer particles in 1 cm³ of dispersion in acetone (m) was found from the following equation:

    m=ρ.sub.s (W.sub.s -W.sub.o)=0.0035 g/ml

Further, the density of polymer particles in dry condition (ρ_(p)) was found according to the following method. The polymer aqueous dispersion A1 was measured with a Lipkin-Davison type pycnometer for the viscosity (ρ_(l)) at 20° C.

ρ_(l) =1.0213 g/ml

From the obtained ρ_(l), ρ_(p) was found from the following equation: ##EQU2## wherein, ρ_(w) : density of water at 20° C. (0.9982 g/ml) and

W_(l) : non-volatile matter of polymer aqueous dispersion A1 (21.1%)

Using the above obtained ρ_(p), η_(s), η_(o) and m, the degree of swelling in acetone (S) was found according to the following equation: ##EQU3##

Manufacturing Examples A2˜A15

Using the same apparatuses as those used in Manufacturing Example A1, the procedure in Manufacturing Example A1 was followed based on the formulations A2˜A15 shown in Table 1, and polymer aqueous dispersions having characteristics shown in Table 1, respectively, were obtained. These dispersions were analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained measured values are shown in Table 1, respectively.

2-A. MANUFACTURE OF POLYMER AQUEOUS DISPERSION (CORE-SHELL TYPE EMULSION POLYMERIZATION) Manufacturing Example A16

    ______________________________________                                         Surfactant aqueous solution                                                    Deionized water             380 parts                                          Rapisol B90 (Note 1)        7.4 parts                                          Polymerization initiator aqueous solution 1                                    Deionized water             10 parts                                           Potassium persulphate       0.25 parts                                         Core-forming α,β-ethylenically unsaturated monomer                  mixture                                                                        Trimethylol propane triacrylate                                                                            6 parts                                            Styrene                     9 parts                                            n-Butyl methacrylate        12 parts                                           Shell-forming α,β-ethylenically unsaturated monomer                 mixture                                                                        2-hydroxypropyl methacrylate                                                                               10 parts                                           Trimethylol propane triacrylate                                                                            14 parts                                           Styrene                     21 parts                                           n-Butyl methacrylate        28 parts                                           Polymerization initiator aqueous solution 2                                    Deionized water             10 parts                                           Potassium persulphate       0.25 parts                                         ______________________________________                                    

The same flask as that used in Manufacturing Example A1 was charged with the surfactant aqueous solution and after raising the temperature to 80° C. under nitrogen stream, polymerization initiator aqueous solution 1 was added. After the temperature had resumed 80° C., as the temperature of the mixture in the flask was kept at 80°±2° C., the core-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 43 minutes and subsequently the shell-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 137 minutes. From 1 hour after the commencement of the addition of the core-forming α,β-ethylenically unsaturated monomer mixture, the polymerization initiator aqueous solution 2 was also added dropwise taking 2 hours, parallel with the addition of the shell-forming α,β-ethylenically unsaturated monomer mixture. After completion of the addition of the α,β-ethylenically unsaturated monomers and polymerization initiator aqueous solution 2, polymerization was further performed at 80° C. for 2 hours to provide polymer aqueous dispersion A16. The non-volatile matter, viscosity and average particle diameter of the obtained polymer aqueous dispersion are shown in Table 2.

Further, the dispersion A16 was analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained measured values are shown in Table 2.

Manufacturing Examples A17˜A22

Using the same apparatuses as those used in Manufacturing Example A1, and following the procedure in Manufacturing Example A16, based on the formulations A17˜A22 shown in Table 2, polymer aqueous dispersions having characteristics shown in Table 2, respectively, were obtained. However, the time required for adding the core- and shell-forming α,β-ethylenically unsaturated monomer mixtures was made to total 3 hours and the time for adding each mixture was made to correspond to the proportion of the monomers occupying the whole mixture.

These dispersions were analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained measured values are shown in Table 2, respectively.

                                      TABLE 1                                      __________________________________________________________________________     Unit: part                                                                                     Manufacturing Example                                                          A1   A2   A3   A4    A5    A6     A7    A8                     __________________________________________________________________________     Deionized water 400  400  400  400   400   400    400   400                    Surfactant (1)  Rapisol                                                                             Sintrex                                                                             Sintrex                                                                             Sintrex                                                                              Rapisol                                                                              Rapisol                                                                               Rapisol                                                                              Aerosol                                B90  L-100                                                                               EHR  EHR   B90   B90    B90   MA80                                   7.4  8.6  7.0  7.0   7.4   7.4    7.4   7.3                    Water-soluble polymerization                                                                   Na.sub.2 S.sub.2 O.sub.8                                                            Na.sub.2 S.sub.2 O.sub.8                                                            Na.sub.2 S.sub.2 O.sub.8                                                            Na.sub.2 S.sub.2 O.sub.8                                                             Na.sub.2 S.sub.2 O.sub.8                                                             K.sub.2 S.sub.2 O.sub.8                                                               K.sub.2 S.sub.2                                                                      K.sub.2 S.sub.2                                                                O.sub.8                initiator       0.5  0.5  0.5  0.5   0.5   0.5    0.5   0.5                    α,β-ethylenically                                                   unsaturated monomer (2)                                                        Component (a)   HEMA HEMA HEMA HEMA  HEMA  HEMA   HEMA  HEMA                                   1.2  2.3  4.6  4.6   9.2   9.2    18.5  18.5                   Active hydroxyl 0    0    0    0     0     0      0     0                      type monomer                                                                   (mol. %)                                                                       Component (b)   EGDM EGDM EGDM EGDM  DEGDM DEGDM  DEGDM DEGDM                                  3    5    10   15    20    30     20    40                     Component (c)   St   St   St   St    St    St     St    St                                     15   15   15   15    30    30     30    30                                     BMA  BMA  EHMA EHMA  i-BMA i-BMA  MMA   MMA                                    80.8 77.7 70.4 65.4  40.8  30.8   31.5  11.5                   Non-volatile matter (%) (3)                                                                    21.1 20.8 21.3 21.1  20.8  20.7   21.1  21.2                   Viscosity (cps) (4)                                                                            28   32   37   39    50    54     65    63                     Average particle dia. (nm) (5)                                                                 72   64   48   39    42    38     40    35                     Hexane tolerance (6)                                                                           38   32   27   27    19    20     7     8                      Degree of swelling in acetone                                                                  9.0  4.4  3.2  2.8   2.6   2.2    2.6   2.1                    (7)                                                                            __________________________________________________________________________     Unit: part                                                                                    Manufacturing Example                                                          A9    A10 A11  A12      A13     A14     A15                     __________________________________________________________________________     Deionized water                                                                               400  400  400  400      400     400     400                     Surfactant (1) Aerosol                                                                             Aerosol                                                                             Aerosol                                                                             Aerosol  Aerosol Aerosol Aerosol                                MA80 MA80 MA80 AY65     AY65    AY65    A268                                   7.3  7.3  7.3  8.3      8.3     8.3     11.5                    Water-soluble polymerization                                                                  K.sub.2 S.sub.2 O.sub.8                                                             K.sub.2 S.sub.2 O.sub.8                                                             K.sub.2 S.sub.2 O.sub.8                                                             (NH.sub.4).sub.2 S.sub.2 O.sub.8                                                        (NH.sub.4).sub.2 S.sub.2 O.sub.8                                                       (NH.sub.4).sub.2 S.sub.2                                                       O.sub.8 (NH.sub.4).sub.2                                                               S.sub.2 O.sub.8         initiator      0.5  0.5  0.5  0.5      0.5     0.5     0.5                     α,β-ethylenically                                                   unsaturated monomer (2)                                                        Component (a)  FM1  HEMA HEMA HEMA     Blemmer PE90                                                                           GMA/Glycolic                                                                           Blemmer GLM                            10   10   5    5        10      acid    1                                           FM4  FM4  Blemmer PP1000   10      GMA/(Lactic                                 10   35    20                      acid).sub.8                                                                    7                       Active hydroxyl                                                                               100  18   61   56       100     100     60                      type monomer                                                                   (mol. %)                                                                       Component (b)  DVB  DVB  DVB  DVB      TMPT    TMPT    TMPT                                   18   18   18   18       15      15      15                      Component (c)  St   St   St   St       St      St      St                                     5    5    5    5        15      15      15                                     BMA  BMA  BMA  CHMA     CHMA    MMA     i-BMA                                  67   57   37   52       60      60      62                      Non-volatile matter (%) (3)                                                                   21.3 20.9 20.8 21.4     21.5    20.9    21.1                    Viscosity (cps) (4)                                                                           62   58   60   54       48      51      45                      Average particle dia. (nm) (5)                                                                53   43   45   51       40      43      38                      Hexane tolerance (6)                                                                          19   10   9    11       16      18      25                      Degree of swelling in acetone                                                                 3.0  3.1  3.1  3.0      2.7     2.6     2.6                     (7)                                                                            __________________________________________________________________________

                                      TABLE 2                                      __________________________________________________________________________                      Unit: part                                                                     Manufacturing Example                                                          A16  A17   A18  A19 A20   A21        A22                      __________________________________________________________________________     Deionized water  400  400   400  400 400   400        400                      Surfactant 1)    Rapisol                                                                             Rapisol                                                                              Rapisol                                                                             Aerosol                                                                            Aerosol                                                                              Aerosol    Aerosol                                   B90  B90   B90  MA80                                                                               MA80  AY65       AY65                                      7.4  7.4   7.4  7.3 7.3   8.3        8.3                      Water soluble polymerization                                                                    K.sub.2 S.sub.2 O.sub.8                                                             K.sub.2 S.sub.2 O.sub.8                                                              K.sub.2 S.sub.2 O.sub.8                                                             Na.sub.2 S.sub.2 O.sub.8                                                           Na.sub.2 S.sub.2 O.sub.8                                                             (NH.sub.4).sub.2 S.sub.2                                                       O.sub.8    (NH.sub.4).sub.2                                                               S.sub.2 O.sub.8          initiator        0.5  0.5   0.5  0.5 0.5   0.5        0.5                      Core-forming α,β-ethylenically                                      unsaturated monomer                                                            Component (b)    TMPT TMPT  EGDM DEGDM                                                                              TMPT  EGDM       DEGDM                                      6   0.4   15   32   6    15         32                       Component (c)    St   St    St   St  St    St         St                                         9    3    15   24   9    15         24                                        BMA  BMA   CHMA MMA BMA   CHMA       MMA                                       12   6.3   15   18.4                                                                               12    15         18.4                     Shell-forming α,β-ethylenically                                     unsaturated monomer 2)                                                         Component (a)    HPMA HPMA  HPMA HPMA                                                                               HPMA  HPMA       HPMA                                      10    3    10    7   5     5          5                                                            FM10  Blemmer-70PEP350B                                                                         GMA/(12HSA).sub.3                                              5     5          2                       Active hydroxyl   0    0     0    0  10    20          5                       type monomer (mol. %)                                                          Component (b)    TMPT TMPT  EGDM DEGDM                                                                              TMPT  EGDM       DEGDM                                     14   3.6   15    8  14    15          8                       Component (c)    St   St    St   St  St    St         St                                        21   27    15    6  21    15          6                                        BMA  BMA   CHMA MMA BMA   CHMA       MMA                                       28   56.7  15   4.6 28    15         4.6                       ##STR6##        30   10    50   80  30    50         80                       Non-volatile matter (%) 3)                                                                      21.3 21.0  20.8 20.7                                                                               20.9  20.5       20.6                     Viscosity (cps) 4)                                                                              62   37    58   61  63    59         60                       Average particle dia. (nm) 5)                                                                   49   60    42   39  47    41         40                       Hexane tolerance 6)                                                                             14   29     9    5  15    11          5                       Degree of swelling in acetone 7)                                                                2.2  6.8   2.1  2.1 2.3   2.2        2.1                      __________________________________________________________________________     Notes in Tables 1 and 2 above                                                  1) Surfactant:                                                                 (a) Rapisol B90 (trade name of sodium di-2-ethylhexyl sulphosuccinate          manufactured by Nippon Oil & Fats Co., Ltd.;                                   active ingredient, 90%),                                                       (b) Sintrex L-100 (trade name of sodium laurylsulphate manufactured by         Nippon Oil & Fats Co., Ltd.; active ingredient, 100%),                         (c) Sintrex EHR (trade name of sodium 2-ethylhexyl sulphate manufactured       by Nippon Oil & Fats Co., Ltd.; active ingredient, 100%),                      (d) Aerosol MA-80 (trade name of sodium dihexyl sulphosuccinate                manufactured by American Cyanamid; active ingredient, 80%),                    (e) Aerosol AY-65 (trade name of sodium diamyl sulphosuccinate                 manufactured by American Cyanamid; active ingredient, 65%), and                (f) Aerosol A-268 (trade name of di-sodium isodecyl sulphosuccinate            manufactured by American Cyanamid; active ingredient, 50%).                    2) α,β-ethylenically unsaturated monomer:                           Component (a):                                                                 HEMA: 2-hydroxyethyl methacrylate,                                             HPMA: 2-hydroxypropyl methacrylate,                                            FM1, FM4 and FM10: Placcel FM1, Placcel FM4 and Placcel FM10 (trade names      of monomers of 1 mole, 4 mol and 10 mole                                       ε-caprolactone adduct, respectively, of 1 mole 2-hydroxyethyl          methacrylate, manufactured by Daicel Chemical Industries, Ltd.),               Blemmer PP1000, Blemmer PE90 and Blemmer 70PEP350B: trade names of             α,β-ethylenically unsaturated monomers                              (manufactured by Nippon Oil & Fats Co., Ltd.) shown by the following           formula:                                                                        ##STR7##                                                                      Blemmer PP1000: m = 0, n = 6,                                                  Blemmer PE90: m = 2, n = 0,                                                    Blemmer 70PEP350B: m = 7, n = 3,                                               Blemmer GLM: trade name of glycerol methacrylate manufactured by Nippon        Oil & Fats Co., Ltd.                                                           GMA/glycolic acid: a glycolic acid adduct of glycidyl methacrylate,            GMA/(lactic acid).sub.8 : adduct of glycidyl methacrylate with 8 mole          condensate of lactic acid, and                                                 GMA/(12HSA).sub.3 : adduct of glycidyl methacrylate with 3 mole                condensate of 12-hydroxystearic acid.                                          Component (b):                                                                 EGDM: ethylene glycol dimethacrylate,                                          DEGDM: diethylene glycol dimethacrylate,                                       DVB: divinyl benzene (purity, 55%: containing 45% of ethyl vinyl               benzene), and                                                                  TMPT: trimethylol propane triacrylate.                                         Component (c):                                                                 St: styrene,                                                                   BMA: n-butyl methacrylate,                                                     EHMA: 2-ethylhexyl methacrylate,                                               i-BMA: isobutyl methacrylate,                                                  MMA: methyl methacrylate, and                                                  CHMA: cyclohexyl methacrylate.                                                 3) In accordance with JIS K 5400 8.2, Non-volatile matter.                     4) Measured by Brookfield viscometer with 60 rpm at 20° C.              5) Measured by "AUTOSIZER" (trade name) manufactured by Malvern.               6) Hexane tolerance: determined by the method of analysis described in         Manufacturing Example A1, item (i).                                            7) Degree of swelling in acetone: determined by the method of analysis         described in Manufacturing Example A1, item (ii).                         

3-A. MANUFACTURE OF POLYMER AQUEOUS DISPERSION (SOAP-FREE EMULSION POLYMERIZATION) Manufacturing Example A23

    ______________________________________                                         Deionized water            280.0 parts                                         Polymerization initiator aqueous solution 1                                    Deionized water            60.0 parts                                          Sodium persulphate         2.0 parts                                           Particle-forming α,β-ethylenically unsaturated                      monomer mixture                                                                2-Hydroxyethyl methacrylate                                                                               9.2 parts                                           Diethylene glycol dimethacrylate                                                                          20.0 parts                                          Styrene                    15.0 parts                                          Isobutyl methacrylate      55.8 parts                                          Polymerization initiator aqueous solution 2                                    Deionized water            60.0 parts                                          Sodium persulphate         2.0 parts                                           ______________________________________                                    

Into the same flask as used in Manufacturing Example A1, deionized water was introduced and after raising the temperature to 80° C., polymerization initiator aqueous solution 1 was added. Then, as the temperature of the mixture in the flask was kept at 80°±2° C., the particle-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 3 hours. From 1 hour after the commencement of the addition and parallel with the addition of this monomer mixture, the polymerization initiator aqueous solution 2 was also added dropwise taking 2 hours. After completion of the addition of the particle-forming α,β-ethylenically unsaturated monomers and polymerization initiator aqueous solution 2, soap-free emulsion polymerization was further conducted at 80° C. for 2 hours to provide polymer aqueous dispersion A23. With respect to the obtained polymer aqueous dispersion, determined values of non-volatile matter, viscosities measured with Brookfield type viscometer at 20° C. and 60 rpm, and average particle diameters measured with "AUTOSIZER" manufactured by Malvern, are shown in Table 3.

                                      TABLE 3                                      __________________________________________________________________________     Unit: part                                                                                     A23   A24   A25  A26                                           __________________________________________________________________________     Deionized water 400   400   400  400                                           Water-soluble polymerization                                                                   Na.sub.2 S.sub.2 O.sub.8                                                             K.sub.2 S.sub.2 O.sub.8                                                              K.sub.2 S.sub.2 O.sub.8                                                             (NH.sub.4).sub.2 S.sub.2 O.sub.8              initiator       4     4     4    4                                             α,β-ethylenically                                                   unsaturated monomer                                                            Component (a)   HEMA  HEMA  FM-1 HEMA                                                          9.2   2.5   7    5                                                                              Blemmer                                                                        20                                            Active hydroxyl 0     0     100  56                                            type monomer                                                                   (mol. %)                                                                       Component (b)   DEGDM DEGDM DVB  DVB                                                           20    20    18   8                                             Component (c)   St    St    St   St                                                            15    15    20   25                                                            i-BMA MMA   BMA  CHMA                                                          55.8  62.5  55   42                                            Non-volatile matter (%)                                                                        20.2  20.3  20.6 20.8                                          Viscosity (cps) 40    53    52   61                                            Average particle dia. (nm)                                                                     265   282   343  369                                           Hexane tolerance                                                                               20    35    27   12                                            Degree of swelling in acetone                                                                  2.8   2.8   3.2  5.7                                           __________________________________________________________________________

Manufacturing Examples A24, A25 and A26

Using the same apparatuses as those used in Manufacturing Example A1, and following the procedure in Manufacturing Example A23, based on the formulations A24, A25 and A26 in Table 3, polymer aqueous dispersions having characteristics shown in Table 3, respectively, were obtained.

Further, these dispersions were analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained measured values are shown in Table 3, respectively.

4-A. MANUFACTURE OF POLYMER AQUEOUS DISPERSION (SOAP-FREE CORE-SHELL TYPE EMULSION POLYMERIZATION) Manufacturing Example A27

    ______________________________________                                         Deionized water           280.0 parts                                          Polymerization initiator aqueous solution 1                                    Deionized water           60.0 parts                                           Potassium persulphate     2.0 parts                                            Core-forming α,β-ethylenically unsaturated                          monomer mixture                                                                Ethylene glycol dimethacrylate                                                                           7.5 parts                                            Styrene                   7.5 parts                                            Cyclohexyl methacrylate   30.0 parts                                           Shell-forming α,β-ethylenically unsaturated                         monomer mixture                                                                2-hydroxypropyl methacrylate                                                                             10.0 parts                                           Ethylene glycol dimethacrylate                                                                           7.5 parts                                            Styrene                   7.5 parts                                            Cyclohexyl methacrylate   30.0 parts                                           Polymerization initiator aqueous solution 2                                    Deionized water           60.0 parts                                           Potassium persulphate     2.0 parts                                            ______________________________________                                    

Into the same flask as used in Manufacturing Example A1, deionized water was introduced and after raising the temperature to 80° C., polymerization initiator aqueous solution 1 was added. Then, as the temperature of the mixture in the flask was kept at 80°±2° C., the core-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 81 minutes and subsequently the shell-forming α,β-ethylenically unsaturated monomer mixture was added dropwise taking 99 minutes. From 1 hour after the commencement of the addition of the core-forming α,β-ethylenically unsaturated monomer mixture and parallel with the addition of core- and shell-forming α,β-ethylenically unsaturated monomer mixtures, the polymerization initiator aqueous solution 2 was also added dropwise taking 2 hours. After completion of the addition of the α,β-ethylenically unsaturated monomer mixture and polymerization initiator aqueous solution 2, soap-free emulsion polymerization was further conducted at 80° C. for 2 hours to provide polymer aqueous dispersion A27. Non-volatile matter, viscosities and average particle diameters of the obtained polymer aqueous dispersion are shown in Table 4.

Further, the dispersion A27 was analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained measured values are shown in Table 4.

Manufacturing Examples A28, A29 and A30

Using the same apparatuses as those used in Manufacturing Example A1, and following the procedure in manufacturing Example A27, based on the formulations A28˜30 shown in Table 4, polymer aqueous dispersions having characteristics shown in Table 4, respectively, were obtained. However, the time required for adding the core- and shell-forming α,β-ethylenically unsaturated monomer mixtures was made to total 3 hours and the time for adding each mixture was made to correspond to the proportion of the monomers occupying the whole mixtures.

These dispersions were analyzed and measured for hexane tolerance and degree of swelling in acetone by exactly the same method as described in Manufacturing Example A1, (i) and (ii). The obtained values are shown in Table 4, respectively.

                                      TABLE 4                                      __________________________________________________________________________                        Unit: part                                                                     A27  A28   A29   A30                                        __________________________________________________________________________     Deionized water    400  400   400   400                                        Water-soluble polymerization initiator                                                            K.sub.2 S.sub.2 O.sub.8                                                             Na.sub.2 S.sub.2 O.sub.8                                                             Na.sub.2 S.sub.2 O.sub.8                                                             (NH.sub.4).sub.2 S.sub.2 O.sub.8                               4    4     4     4                                         Core-forming α,β-ethylenically                                      unsaturated monomer                                                            Component (b)      EGDM DEGDM TMPT  EGDM                                                          7.5  2.4    6     1                                         Component (c)      St   St    St    St                                                            7.5  12     9     3                                                            CHMA MMA   BMA   CHMA                                                          30   57.6  12    3.5                                        α,β-ethylenically unsaturated monomer                               Component (a)      HPMA HPMA  HPMA  HPMA                                                          10   10     5     5                                                                       FM10  Blemmer                                                                        PP1000                                                                    5    20                                         Active hydroxyl     0    0    10    56                                         type monomer (mol. %)                                                          Component (b)      EGDM DEGDM TMPT  EGDM                                                          7.5  0.6   14     9                                         Component (c)      St   St    St    St                                                            7.5   3    21    27                                                            CHMA MMA   BMA   CHMA                                                          30   14.4  28    31.5                                        ##STR8##          50   80    30    10                                         Non-volatile matter (%)                                                                           20.4 20.2  20.3  20.5                                       Viscosity (cps)    48   71    55    48                                         Average particle dia. (nm)                                                                        273  381   317   297                                        Hexane tolerance   10    9    16    10                                         Degree of swelling in acetone                                                                     3.1  9.2   2.4   3.4                                        __________________________________________________________________________

1-B. MANUFACTURE OF POLYMER NON-AQUEOUS DISPERSION (CONVERSION OF POLYMER AQUEOUS DISPERSIONS 1-A AND 2-A TO NON-AQUEOUS SYSTEM) Manufacturing Example B1

Into a flask equipped with a stirrer, a reflux condenser, a dropping funnel and a thermometer, 1,000 parts of component A1, 400 parts of methylpentyl ketone and 45.3 parts of 3N-NaOH aqueous solution were introduced and the temperature was raised to 85° C. A hydrolysis reaction was carried out at 85°±2° C. for 3 hours. Then the temperature was lowered to 80° C. and after adding 45.3 parts of 3N-hydrochloric acid aqueous solution to neutralize, 143 parts of acrylic resin solution A (referred to hereinafter) were added as a particle dispersion stabilizing resin. After stirring for 10 minutes, 50 parts of triethylamine acetate 20% aqueous solution were added and immediately thereafter the stirring was stopped to leave the dispersion to stand still. Since an organic layer wherein polymer particles were dispersed was separated above from a lower water layer, the water layer was removed.

To the remaining organic layer wherein the polymer particles were dispersed, 400 parts of deionized water were added and the temperature was raised to 70° C. while stirring. When 70° C. was reached, 25 parts of triethylamine acetate 20% aqueous solution were added and immediately thereafter the stirring was stopped to leave the dispersion to stand still. Since the dispersion was again separated into two layers: an upper organic layer wherein polymer particles were dispersed and a lower water layer, the lower water layer was removed. In the remaining organic layer, 2.6% by weight of residual water were determined by Karl Fischer moisture meter.

Then the organic layer was cooled down to 50° C. After 114 parts of methyl orthoformate were added dropwise from the dropping funnel taking 30 minutes, the reaction was continued at 50° C. for 30 minutes, and then 200 parts of xylene were added. Newly fixing a Dean & Stark apparatus between the reflux condenser and the flask, connecting the upper part of the reflux condenser with an aspirator, the inside pressure of the flask was reduced while heating and stirring to distill off 504 parts of solvents at 80°±10° C. under 300±100 mmHg, and polymer non-aqueous dispersion B1 was obtained.

With respect to the obtained polymer non-aqueous dispersion, determined values of non-volatile matter, viscosities measured with Brookfield type viscometer at 20° C. and 60 rpm, average particle diameters measured with "AUTOSIZER" manufactured by Malvern, and water contents measured with Karl Fischer moisture meter, are shown in Table 5.

(i) Determination of Total Ion Content of Polymer Particle

Polymer non-aqueous dispersion B1 was diluted accurately 5 times with a mixed solvent of acetone/water=9/1 (weight ratio) by using a transfer pipette and a measuring flask, and dispersed therein. This diluted dispersion was passed at a rate of 50 parts per minute through a glass tube column having an inside diameter of 30 mm charged with Dia-ion SK-1B (trade name of a cation exchange resin manufactured by Mitsubishi Chemical Industries, Ltd.) which had previously been regenerated to acidic type (water in the column had previously been replaced by a mixed solvent of acetone/water=9/1 passed therethrough), to ion-exchange all of residual surfactants and polymerization initiator fragments in the dispersion. Then, acids in the dispersion were quantitatively analyzed with a potentiometric titration apparatus AT210 (trade name manufactured by Kyoto Electronics Manufacturing Co., Ltd.) using 0.1N--KOH ethanol solution as a standard solution.

    Total ionic group concentration per solid matter in the diluted dispersion=6.151×10.sup.-5 mol/g

Then, the ionic group concentration per solid matter of acrylic resin A was quantitatively analyzed with the potentiometric titration apparatus.

    Ionic group concentration per solid matter of acrylic resin=1.852×10.sup.-4 mol/g

By means of potentiometric titration analysis, sulphonate and sulphate ions are detectable separately from carboxylate ion, whereas in the above test samples none of sulphonate and sulphate ions was detected. Accordingly, from the result of the above analyses, the total ionic group concentration of polymer particles in polymer non-aqueous dispersion B1 which had only carboxylate ion was found as follows: ##EQU4##

Namely, it was found that in polymer non-aqueous dispersion B1, there existed none of sulphonate and sulphate ions arising from Rapisol B90 and sodium persulphate, respectively, used in the emulsion polymerization, and only carboxylate ion produced by hydrolysis of a trace amount of the polymer particle was detected.

(ii) Determination of Na Ion

Polymer non-aqueous dispersion B1 was shaken with an equal quantity by weight of 0.2 N--HCl aqueous solution in a separatory funnel to extract Na ion entirely from the dispersion B1. This extract liquid was diluted accurately 10 times with deionized water by using a transfer pipette and a measuring flask and Na ion concentration was quantitatively determined by an atomic-absorption spectroscope, AA-670G V-6 (trade name, manufactured by Shimadzu Corporation). As a result, it was found that 28 ppm of Na ion existed in the dispersion B1 before extraction.

This Na ion concentration is equivalent to 0.5 mole % of the total amount of Rapisol B90 and sodium persulphate used in the emulsion polymerization and NaOH used in the hydrolysis step, so that a balance of 99.5 mole % were accounted to have been washed away out of the system.

Manufacturing Examples B2˜B4, B8, B9, B16˜B20

Using the same apparatuses as those used in Manufacturing Example B1, the procedure in manufacturing Example B1 was followed based on the formulations shown in Manufacturing Examples B2˜B4, B8 and B9 in Table 5 and Manufacturing Examples B16˜B19 in Table 6, and polymer non-aqueous dispersions B2˜B4, B8 B9 B16˜B20 having characteristics shown in Tables 5 and 6, respectively, were obtained.

Further, these dispersions were analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Tables 5 and 6, respectively, were determined. Additionally, no K ion was detected in dispersions B8, B9, B16, B17 and B18.

Manufacturing Examples B5˜B7, B21˜B24

Using a flask equipped with a stirrer, a reflux condenser and a thermometer, and following the procedure in Manufacturing Example B1, based on the formulations shown in Manufacturing Examples B5˜B7 in Table 5 and Manufacturing Examples B21˜B24 in Table 6, an organic layer wherein polymer particles were dispersed was washed with water, the water layer in separated two layers was removed and then newly fixing a Dean & Stark apparatus between the flask and the reflux condenser, a predetermined amount of water and solvent was distilled off at 80°±10° C. under a reduced pressure of 300±100 mmHg from the organic layer containing residual water, whereby polymer non-aqueous dispersions B5˜B7 and B21˜B24 having characteristics shown in Tables 5 and 6, respectively, were obtained.

Further, these dispersions were analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Tables 5 and 6, respectively, were determined. Additionally, no K ion was detected in dispersions B6 and B7.

Manufacturing Example B10

Using the same apparatuses as those used in Manufacturing Example B1, the procedure in Manufacturing Example B1 was followed based on the formulations shown in Manufacturing Example B10 in Table 5, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then raising the temperature to 90° C., 45 parts of formamide were added dropwise from the dropping funnel taking 30 minutes, and further the reaction was continued at 90° C. for 3 hours. Then, using the same apparatuses as used in Manufacturing Example B1, 171 parts of solvent were distilled off under a reduced pressure, and cooling down to 50° C., produced ammonium formate was filtered off, whereby polymer non-aqueous dispersion B10 having characteristics shown in Table 5 was obtained.

Further, the obtained dispersion B10 was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Table 5 were determined. Additionally, no K ion was detected in the dispersion.

Manufacturing Example 11

Using the same apparatuses as those used in Manufacturing Example B1, the procedure in Manufacturing Example B1 was followed based on the formulations shown in Manufacturing Example B11 in Table 5, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then cooling down to 50° C., 223 parts of dicyclohexyl carbodiimide were added little by little taking 30 minutes, and further the reaction was continued at 50° C. for 1 hour. Then, 200 parts of xylene were added and using the same apparatuses as used in Manufacturing Example B1, 371 parts of solvent were distilled off under a reduced pressure. Thus produced dicyclohexyl urea was filtered off to obtain polymer non-aqueous dispersion B11 having characteristics shown in Table 5.

Further, the obtained dispersion B11 was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Table 5 were determined. Additionally, no K ion was detected in the dispersion.

Manufacturing Examples B12˜B14

Using a flask equipped with a stirrer, a reflux condenser and a thermometer, and following the procedure in Manufacturing Example B1, based on the formulations shown in Manufacturing Examples B12˜B14 in Table 5, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then the organic layer containing residual water was passed at a rate of 50 parts per minute through a glass tube column having an inside diameter of 30 mm charged with a predetermined amount of a polymer water absorbent or a molecular sieve. Thereafter, using the same apparatuses as used in Manufacturing Example B1, a predetermined amount of solvent was distilled off under a reduced pressure to obtain polymer non-aqueous dispersions B12˜B14 having characteristics shown in Table 5.

Further, the obtained each dispersion was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentration in polymer particle and Na ion concentration in dispersion shown in Table 5 were determined.

Manufacturing Example B15

Using a flask equipped with a stirrer, a reflux condenser and a thermometer, and following the procedure in Manufacturing Example B1, based on the formulation shown in Manufacturing Example B15 in Table 5, an organic layer wherein polymer particles were dispersed was washed with water and the water layer in separated two layers was removed. After adding 164 parts of Na₂ SO₄ powder, stirring was conducted for 3 hours. Then using the same apparatuses as used in Manufacturing Example B1, a predetermined amount of solvent was distilled off under a reduced pressure. By filtering after cooling down to 50° C., polymer non-aqueous dispersion B15 having characteristics shown in Table 5 was obtained.

Further, the obtained dispersion B15 was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentration in polymer particle and Na ion concentration in dispersion shown in Table 5 were determined.

    TABLE 5       Unit: part Manufacturing Example   B1 B2 B3 B4 B5 B6 B7 B8        Hydrolysis Polymer aqueous dispersion A1 A2 A3 A4 A5 A6 A7 A8 step      1000  1000  1000  1000  1000  1000  1000  1000  Organic Methylpentyl      ketone 400 400 400 400     solvent n-Butyl alcohol     280 280 280      4-Methyl-2-pentyl alcohol        280  Methyl-isobutyl ketone  Xylene      120 120 120 120 Basic 3N--NaOH aq. solution   45.3   45.3   45.3   45.3       45.3   45.3   45.3   45.3 compound (molar ratio) 1) (2) (2) (2) (2) (2)      (2) (2) (2) catalyst Heating conditions 85° C. 85° C.      85° C. 85° C. 85° C. 85° C. 85° C.      85° C.  3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs.      Acidic 3N--HCl aq. solution   45.3   45.3   45.3   45.3   45.3   45.3      45.3   45.3  compound Neutral- Dispersion Acrylic resin A 143 143 143      143 ization stabilizing Acrylic resin B     143 143 143 143 stabilizing      resin 2) Particle/resin 70/30 70/30 70/30 70/30 70/30 70/30 70/30 70/30      step Water Amine salt of organic acid 3) Acetic Acetic Acetic Acetic      Acetic Formic acid/ Formic acid/ Formic acid/ separation (20% aq.      solution) acid/TEA acid/TEA acid/TEA acid/TEA acid/TEA pyridine pyridine      pyridine step   50  50  50  50  50  50  50  50 Water- Deionized water      400 400 400 400 400 400 400 400 washing Amine salt of organic acid 3)      Acetic Acetic Acetic Acetic Acetic Formic acid/ Formic acid/ Formic      acid/ step (20% aq. solution) acid/TEA acid/TEA acid/TEA acid/TEA      acid/TEA pyridine pyridine pyridine    25  25  25  25  25   25  25  25      Residual water 4)    2.6    2.8    2.2    2.4   14.5   14.2   15.0      3.2 Residual Method 5) Methyl Methyl Methyl Methyl Vacuum Vacuum Vacuum      Diketene water re-  orthoformate orthoformate orthoformate orthoformate      distillation distillation distillation 111 moving step  114 123  96 105      300 ± 100 mmHg 300 ± 100 mmHg 300 ± 100 mmHg       80 ±      10° C. 80 ± 10° C. 80 ± 10° C. Desolvation      Amount of xylene added 200 200 200 200    200 step Amount of desolvation      504 515 483 494 279 11) 277 11) 282 11) 506 Character- Non-volatile      matter (%) 6)   50.2   50.4   51.0   50.8   51.1   50.8   50.7   50.5      istics of Viscosity (cps) 7) 543 465 373 382 435 443 472 470 polymer      Average particle dia. (nm) 8)  83  72  61  42  45  41  43  38 non-aq.      Water content (%) 4)    0.1    0.1    0.1    0.1    0.4    0.4    0.4      0.1 dispersion Total ionic group concentra- 0.85 × 10.sup.-5 0.73      × 10.sup.-5 0.98 × 10.sup.-5 0.82 × 10.sup.-5 0.81      × 10.sup.-5 0.74 × 10.sup.-5 0.93 × 10.sup.-5 0.94      × 10.sup.-5  tion of polymer particles  (mol/g particle) 9)  Na      ion concentration (ppm) 10)  28  26  31  29  30  27  32       26                Unit: part Manufacturing Example   B9 B10 B11 B12 B13 B      14 B15        Hydrolysis Polymer aqueous dispersion A9 A10 A11 A12 A13 A14 A15 step      1000  1000  1000  1000  1000  1000  1000  Organic Methylpentyl ketone          solvent n-Butyl alcohol  4-Methyl-2-pentyl-alcohol 280 280 280      Methyl-isobutyl ketone    400 400 400 400  Xylene 120 120 120 Basic      3N--NaOH aq. solution   45.3   45.3   45.3   34.0   34.0   56.7   31.7      compound (molar ratio)  (1)  (2)  (2)  (2)   (1.5)   (1.5)   (2.5)      (2.5) catalyst Heating conditions 85° C. 85° C. 85°      C. 85° C. 85° C. 85° C. 85° C.  3 Hrs. 3      Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs.  Acidic 3N--HCl aq. solution      45.3   45.3   45.3   34.0   34.0   56.7   31.7  compound Neutral-      Dispersion Acrylic resin A 143 143 143 ization stabilizing Resimene 755         86  86  86  86 stabilizing resin 2) Particle/resin 70/30 70/30 70/30      70/30 70/30 70/30 70/30 step Water Amine salt of organic acid 3) Formic      acid/ Formic acid/ Formic acid/ Acetic Formic Formic Formic separation      (20% aq. solution) pyridine pyridine pyridine acid/TMA acid/TMA acid/TMA      acid/TMA step   50  50  50  50  50  50  50 Water- Deionized water 400      400 400 400 400 400 400 washing Amine salt of organic acid 3) Formic      acid/ Formic acid/ Formic acid/ Formic Formic Formic Formic step (20%      aq. solution) pyridine pyridine pyridine acid/TMA acid/TMA acid/TMA      acid/TMA    25  25  25  25  25  25  25  Residual water 4)    2.7    2.4        2.6    2.5    2.9    2.1    2.8 Residual Method 5) Diketene Formamide      Dicyclohexyl Sumika Gel Sumika Gel Molecular Na.sub.2 SO.sub.4 water re-        93  45 carbodiimide S50 S50 sieve 4Al/8 moving step    223  10  10  20      164 Desolvation Amount of xylene added 200  200 step Amount of desolvatio      n 484 171 371 114 114 114 114 Character- Non-volatile matter (%) 6)      50.2   49.9   50.2    50.1   50.2   50.0   49.8 istics of Viscosity      (cps) 7) 458 449 454 444 425 430 413 polymer Average particle dia. (nm)      8)  55  49  53  55  45  47  42 non-aq. Water content (%) 4)    0.1      0.1    0.1    0.4    0.3    0.2    0.3 dispersion Total ionic group      concentra- 0.90 × 10.sup.-5 0.88 × 10.sup.-5 0.92 ×      10.sup.-5 0.57 × 10.sup.-5 0.61 × 10.sup.-5 1.23 ×      10.sup.-5 1.27 × 10.sup.-5  tion of polymer particles  (mol/g      particle) 9)  Na ion concentration (ppm) 10)  30  25  26  24  31  33      26

                                      TABLE 6                                      __________________________________________________________________________     Unit: part                                                                     __________________________________________________________________________                     Manufacturing Example                                                          B16    B17     B18    B19     B20    B21                       __________________________________________________________________________     Hydrolysis step                                                                Polymer aqueous dispersion                                                                     A16    A17     A16    A18     A19    A20                                       1000   1000    1000   1000    1000   1000                      Organic solvent                                                                Methylpentyl ketone                                                                            400    400     400    400     400                              n-Butyl alcohol                                      120                       Xylene                                               280                       Basic compound catalyst                                                        3N--NaOH aq. solution                                                                          45.3   45.3    45.3   45.3    45.3   45.3                      (molar ratio) 1)                                                                               (2)    (2)     (2)    (2)     (2)    (2)                       Heating conditions                                                                             85° C.                                                                         85° C.                                                                          85° C.                                                                         85° C.                                                                          85° C.                                                                         85° C.                             3 Hrs. 3 Hrs.  3 Hrs. 3 Hrs.  3 Hrs. 3 Hrs.                     Neutralization stabilizing step                                               Acidic compound 45.3   45.3    45.3   45.3    45.3   45.3                      3N--HCl aq. solution                                                           Dispersion stabilizing resin 2)                                                Acrylic resin B 143                                  143                       Alkyd resin C          143     143    143     143                              Cymel 1171                                                                     Particle/resin  70/30  70/30   70/30  70/30   70/30  70/30                      Water separation step                                                         Amine salt of organic acid 3)                                                                  Acetic Acetic  Acetic Acetic  Acetic acid/                                                                          Formic acid/              (20% aq. solution)                                                                             acid/TEA                                                                              acid/TEA                                                                               acid/TEA                                                                              acid/TEA                                                                               TEA    pyridine                                   50     50      50     50      50     50                        Water-washing step                                                            Deionized water 400    400     400    400     400    400                       Amine salt of organic acid 3)                                                                  Acetic Acetic  Acetic Acetic  Acetic acid/                                                                          Formic acid/              (20% aq. solution)                                                                             acid/TEA                                                                              acid/TEA                                                                               acid/TEA                                                                              acid/TEA                                                                               TEA    pyridine                                   25     25      25     25      25     25                       Residual water (%) 4)                                                                           2.7    2.2     2.7    2.3     2.4    3.2                       Residual water removing step                                                  Method 5)       Methyl Methyl  Methyl Methyl  Methyl Vacuum                                    orthoformate                                                                          orthoformate                                                                           orthoformate                                                                          orthoformate                                                                           orthoformate                                                                          distillation                              119     96     119    101     105    300 ± 100 mmHg                                                              80 ± 10°                                                             C.                         Desolvation step                                                              Amount of xylene added                                                                         200    200     200    200     200                              Amount of desolvation                                                                          510    483     510    489     494       195 11)                Characteristics of polymer                                                     non-aqueous dispersion                                                         Non-volatile matter (%) 6)                                                                     50.4   50.1    50.3   50.7    50.3   51.3                      Viscosity (cps) 7)                                                                             463    495     460    451     464    472                       Average particle dia. (nm) 8)                                                                   51     78      50     44      40     49                       Water content (%) 4)                                                                            0.1    0.1     0.1    0.1     0.1    0.4                      Total ionic group concen-                                                                      0.92 × 10.sup.-5                                                                0.85 × 10.sup.-5                                                                 0.90 × 10.sup.-5                                                                0.87 × 10.sup.-5                                                                 1.01 × 10.sup.-5                                                                0.88 ×                                                                   10.sup.-5                 tration of polymer particles                                                   (mol./g particle) 9)                                                           Na ion concentration (ppm) 10)                                                                  32     31      30     28      27     28                       __________________________________________________________________________                                         Manufacturing Example                                                          B22      B23      B24                      __________________________________________________________________________                          Hydrolysis step                                                                Polymer aqueous dispersion                                                                    A20      A21      A22                                                          1000     1000     1000                                          Organic solvent                                                                Methylpentyl ketone                                                            n-Butyl alcohol                                                                               120      120      120                                           Xylene         280      280      280                                           Basic compound catalyst                                                        3N--NaOH aq. solution                                                                         45.3     45.3     45.3                                          (molar ratio) 1)                                                                              (2)      (2)      (2)                                           Heating conditions                                                                            85° C.                                                                           85°                                                                              85° C.                                                3 Hrs.   3 Hrs.   3 Hrs.                                         Neutralization stabilizing step                                               Acidic compound                                                                               45.3     45.3     45.3                                          3N--HCl aq. solution                                                           Dispersion stabilizing resin 2)                                                Acrylic resin B                                                                Alkyd resin C  143      143                                                    Cymel 1171                        90                                           Particle/resin 70/30    70/30    70/30                                          Water separation step                                                         Amine salt of organic acid 3)                                                                 Formic acid/                                                                            Formic acid/                                                                            Formic acid/                                  (20% aq. solution)                                                                            pyridine pyridine pyridine                                                      50       50       50                                            Water-washing step                                                            Deionized water                                                                               400      400      400                                           Amine salt of organic acid 3)                                                                 Formic acid/                                                                            Formic acid/                                                                            Formic acid/                                  (20% aq. solution)                                                                            pyridine pyridine pyridine                                                      25       25       25                                           Residual water (%) 4)                                                                          3.2      2.8      2.9                                           Residual water removing step                                                  Method 5)      Vacuum   Vacuum   Vacuum                                                       distillation                                                                            distillation                                                                            distillation                                                 300 ± 100 mmHg                                                                       300 ± 100                                                                            300 ± 100 mmHg                                            80 ± 10° C.                                                                   80 ± 10° C.                                                                   80 ± 10°                                                             C.                                             Desolvation step                                                              Amount of xylene added                                                         Amount of desolvation                                                                            195 11)                                                                                 192 11)                                                                                 138 11)                                    Characteristics of polymer                                                     non-aqueous dispersion                                                         Non-volatile matter (%) 6)                                                                    51.0     51.2     50.8                                          Viscosity (cps) 7)                                                                            468      453      460                                           Average particle dia. (nm) 8)                                                                  47       43       45                                           Water content (%) 4)                                                                           0.4      0.3      0.4                                          Total ionic group concen-                                                                     0.89 × 10.sup.-5                                                                  0.93 × 10.sup.-5                                                                  0.91 ×                                                                   10.sup.-5                                     tration of polymer particles                                                   (mol./g particle) 9)                                                           Na ion concentration (ppm) 10)                                                                 29       26       29                      __________________________________________________________________________     Notes in Tables 5 and 6 above                                                  1) Molar ratio of NaOH aqueous solution: A molar ratio of NaOH to the sum      total of a total amount of ester groups in ester group                         containing surfactants contained in polymer aqueous dispersion and a           double amount of water-soluble polymerization initiator.                       2) Dispersion stabilizing resin:                                               Acrylic resin A: A reactor equipped with a stirrer, a thermometer, a           reflux condenser, a nitrogen gas feed pipe and a                               dropping funnel, was charged with 42 parts of xylene and heated while          stirring, as feeding nitrogen gas. When the temperature                        reached 140° C., the mixture of the monomer components and the          polymerization initiator shown below was dropped at a constant                 rate from the dropping funnel taken 2 hours, as keeping a constant             temperature of 140° C.                                                  n-Butyl methacrylate                                                                         36.4                                                                              parts                                                         2-Ethylhexyl methacrylate                                                                    11.7                                                                               "                                                            2-Hydroxyethyl methacrylate                                                                  11.1                                                                               "                                                            Acrylic acid  0.8                                                                                "                                                            t-Butyl peroxybenzoate                                                                       3.0                                                                                "                                                            Total         63.0                                                                              parts                                                         After the dropping was completed, the contents were kept at 140°        C. for 2 hours before cooled down and taken out. The non-volatile              matter was 60% and the number average molecular weight was 6,500.              Acrylic resin B: Using the same apparatuses as those used in the               preparation of Acrylic resin A, the same procedure was followed                based on the formulations shown below, and Acrylic resin B having 60%          non-volatile matter and a number average molecular                             weight of 7,000 was obtained.                                                  Xylene        42 parts                                                         Styrene       16.8                                                                               "                                                            2-Ethylhexyl methacrylate                                                                    28.5                                                                               "                                                            2-Hydroxyethyl methacrylate                                                                  13.9                                                                               "                                                            Acrylic acid  0.8                                                                                "                                                            t-Butyl peroxybenzoate                                                                       3.0                                                                                "                                                            Total         105                                                                               parts                                                         Alkyd resin C: A flask equipped with a stirrer, a thermometer, a nitrogen      gas feed pipe and a Dean & Stark apparatus provided                            with a reflux condenser, was charged with the monomers shown below and         heated to raise the temperature up to 200° C. while                     stirring, as feeding nitrogen gas. When the acid value reached 10 at a         constant temperature of 200° C., the reaction was stopped               and the reactants were cooled down. When 100° C. was reached, 36        parts of xylene were added to dilute the contents which were                   further cooled down and taken out. The non-volatile matter was 60%, the        number average molecular weight was 1,500, the acid                            value of resin was 10 and the hydroxyl value was 150.                          Soybean oil fatty acid                                                                    12 parts                                                            Isophthalic acid                                                                          18  "                                                               Trimethylol propane                                                                       16.6                                                                               "                                                               Adipic acid                                                                               7.2                                                                                "                                                               Neopentyl glycol                                                                          6.2                                                                                "                                                               Total      60 parts                                                            Resimene 755: Trade name of a methyl/butyl mix-etherified melamine resin       having 100% non-volatile matter, manufactured by                               Monsanto.                                                                      Cymel 1171: Trade name of a glycoluryl resin having 95% non-volatile           matter, manufactured by American Cyanamid.                                     3) Amine salt of organic acid: An amine salt of organic acid 20% aqueous       solution was prepared by dissolving an organic acid into                       deionized water and adding an amine thereto while stirring, with the           formulations shown below.                                                                        Formic acid/                                                          Acetic acid/TEA                                                                         pyridine  Formic acid/TMA                                    Deionized water                                                                                80        80        80                                         organic acid                                                                            acetic acid                                                                           11.8                                                                             Formic acid                                                                            7.4                                                                              Formic acid                                                                            10                                         Amine    TEA    8.2                                                                              Pyridine                                                                               12.6                                                                             TMA     10                                                        100       100       100                                         TEA: Triethyl amine                                                            TMA: Trimethyl amine                                                           4) Measured with KF-05 type moisture meter manufactured by Mitsubishi          Chemical Industries, Ltd.                                                      5) Sumika Gel S50: Trade name of a polymer water absorbent manufactured        by Sumitomo Chemical Co., Ltd.                                                 6), 7) and 8) As aforecited.                                                   9) Total ionic group concentration of polymer particle: Measured in            accordance with the analysis method described in Manufacturing                 Example B1, (i).                                                               10) Na ion concentration: Total amount of Na ion in polymer non-aqueous        dispersion, measured in accordance with the analysis                           method described in Manufacturing Example B1, (ii).                            11) Water contents in the removed solvents in Manufacturing Examples           B5˜B7 and B21˜B24 are shown below, respectively.                   B5 108                                                                               parts                                                                    B6 106                                                                                "                                                                       B7 111                                                                                "                                                                       B21                                                                               24  "                                                                       B22                                                                               24  "                                                                       B23                                                                               21  "                                                                       B24                                                                               20  "                                                                  

2B. MANUFACTURE OF POLYMER NON-AQUEOUS DISPERSION (CONVERSION OF POLYMER AQUEOUS DISPERSIONS 3-A AND 4-A TO NON-AQUEOUS SYSTEM) Manufacturing Examples B25, B26 and B27

Using the same apparatuses as those used in Manufacturing Example B1, the procedure in Manufacturing Example B1 was followed based on the formulations shown in Manufacturing Examples B25, B26 and B27 in Table 7, and polymer non-aqueous dispersions B25, B26 and B27 having characteristics shown in Table 7, respectively, were obtained.

Further, these dispersions were analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Table 7, respectively, were determined. Additionally, no K ion was detected in dispersions B26 and B27.

Manufacturing Example B28

Using a flask equipped with a stirrer, a reflux condenser and a thermometer and following the procedure in Manufacturing Example B1, based on the formulation shown in Manufacturing Example B28 in Table 7, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then newly fixing a Dean & Stark apparatus between the flask and the reflux condenser, a predetermined amount of water and solvent was distilled off at 80°±10° C. under a reduced pressure of 300±100 mmHg from the organic layer containing residual water, whereby polymer non-aqueous dispersion B28 having characteristics shown in Table 7 was obtained.

Further, the dispersion was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentration in polymer particle and Na ion concentration in dispersion shown in Table 7 were determined.

Manufacturing Example B29

Using the same apparatuses as those used in Manufacturing Example B1, the procedure in Manufacturing Example B1 was followed based on the formulation shown in Manufacturing Example B29 in Table 7. An organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then raising the temperature to 90° C., 47 parts of formamide were added dropwise from the dropping funnel taking 30 minutes, and further the reaction was continued at 90° C. for 3 hours. Then, using the same apparatuses as used in manufacturing Example B1, 171 parts of solvent were distilled off under a reduced pressure. After cooling down to 50° C., produced ammonium formate was filtered off to obtain polymer non-aqueous dispersion B29 having characteristics shown in Table 7.

Further, the obtained dispersion was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentration in polymer particle and Na ion concentration in dispersion shown in Table 7 were determined. Additionally, no K ion was detected.

Manufacturing Examples B30 and B31

Using a flask equipped with a stirrer, a reflux condenser and a thermometer and following the procedure in Manufacturing Example B1, based on the formulations shown in Manufacturing Examples B30 and B31 in Table 7, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then the organic layer containing residual water was passed at a rate of 50 parts per minute through a glass tube column having an inside diameter of 30 mm charged with a predetermined amount of a polymer water adsorbent or a molecular sieve. Thereafter, using the same apparatuses as used in Manufacturing Example B1, a predetermined amount of solvent was distilled off under a reduced pressure to obtain polymer non-aqueous dispersions B30 and B31 having characteristics shown in Table 7.

Further, the obtained each dispersion was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentration in polymer particle and Na ion concentration in dispersion shown in Table 7 were determined.

Manufacturing Example B32

Using a flask equipped with a stirrer, a reflux condenser and a thermometer, and following the procedure in Manufacturing Example B1, based on the formulation shown in Manufacturing Example B32 in Table 7, an organic layer wherein polymer particles were dispersed was washed with water, and the water layer in separated two layers was removed. Then a predetermined amount of Na₂ SO₄ powder was added and stirring was conducted for 3 hours. Thereafter, using the same apparatuses as used in Manufacturing Example B1, a predetermined amount of solvent was distilled off under a reduced pressure. By filtering after cooling down to 50° C., polymer non-aqueous dispersion B32 having characteristics shown in Table 7 was obtained.

Further, the obtained dispersion B32 was analyzed by exactly the same method as described in Manufacturing Example B1, (i) and (ii), and total ionic group concentrations in polymer particle and Na ion concentrations in dispersion shown in Table 7 were determined.

                                      TABLE 7                                      __________________________________________________________________________                   Unit: part                                                                     Manufacturing Example                                                          B25    B26    B27    B28                                         __________________________________________________________________________     Hydrolysis step                                                                Polymer aqueous dispersion                                                                   A23    A24    A25    A26                                                       1000   1000   1000   1000                                        Organic solvent                                                                n-Butyl alcohol                    280                                         4-Methyl-2-pentyl alcohol                                                                    280    280    280                                                Methylpentyl ketone                                                            Xylene        120    120    120    120                                         Basic compound catalyst                                                        3N--NaOH aq. solution                                                                        11.2    9.9    9.9   11.7                                        (molar ratio) (2)    (2)    (2)     (1.5)                                      Heating conditions                                                                           85° C.                                                                         85° C.                                                                         85° C.                                                                         85° C.                                             3 Hrs. 3 Hrs. 3 Hrs. 3 Hrs.                                      Neutralization stabilizing step                                                Acidic compound                                                                              11.2    9.9    9.9   11.7                                        3N--HCl aq. solution                                                           Dispersion stabilizing resin                                                   Acrylic resin A                                                                              143    143                                                       Acrylic resin B             143    143                                         Alkyd resin C                                                                  Particle/resin                                                                               70/30  70/30  70/30  70/30                                       Water separation step                                                          Amine salt of organic acid                                                                   Acetic Formic acid/                                                                          Formic acid/                                                                          Formic                                      (20% aq. solution)                                                                           acid/TEA                                                                              pyridine                                                                              pyridine                                                                              acid/TMA                                                   50     50     50     50                                         Water-washing step                                                             Deionized water                                                                              400    400    400    400                                         Amine salt of organic acid                                                                   Acetic Formic acid/                                                                          Formic acid/                                                                          Formic                                      (20% aq. solution)                                                                           acid/TEA                                                                              pyridine                                                                              pyridine                                                                              acid/TMA                                                   25     25     25     25                                         Residual water (%)                                                                            2.8    2.4    2.7   14.5                                        Residual water removing step                                                   Method        Methyl Methyl Diketene                                                                              Vacuum                                                    orthoformate                                                                          orthoformate                                                                           93    distillation                                              123    105           300 ± 100 mmHg                                                              80 ± 10° C.                       Desolvation step                                                               Amount of xylene added                                                                       200    200    200                                                Amount of desolvation                                                                        515    494    484    279                                         Characteristics of polymer non-aqueous dispersion                              Non-volatile matter (%)                                                                      50.1   50.3   50.5   50.1                                        Viscosity (cps)                                                                              437    188    214    482                                         Average particle dia. (nm)                                                                   293    304    362    463                                         Water content (%)                                                                             0.1    0.1    0.1    0.4                                        Total ionic group concen-                                                                    0.81 × 10.sup.-5                                                                0.94 × 10.sup.-5                                                                0.72 × 10.sup.-5                                                                0.90 × 10.sup.-5                      tration of polymer                                                             particles (mol./g particle)                                                    Na ion concentration (ppm)                                                                    27     28     30     26                                         __________________________________________________________________________                   Unit: part                                                                     Manufacturing Example                                                          B29    B30      B31    B32                                       __________________________________________________________________________     Hydrolysis step                                                                Polymer aqueous dispersion                                                                   A27    A28      A29    A30                                                     1000   1000     1000   1000                                      Organic solvent                                                                N-Butyl alcohol                      120                                       4-Methyl-2-pentyl alcohol                                                      Methylpentyl ketone                                                                          400    400      400                                              Xylene                               280                                       Basic compound catalyst                                                        3N--NaOH aq. solution                                                                         9.9   11.2     11.2   11.7                                      (molar ratio)  (2.5) (2)      (2)    (2)                                       Heating conditions                                                                           85° C.                                                                         85° C.                                                                           85° C.                                                                         85° C.                                           3 Hrs. 3 Hrs.   3 Hrs. 3 Hrs.                                    Neutralization stabilizing step                                                Acidic compound                                                                               9.9   11.2     11.2   11.7                                      3N--HCl aq. solution                                                           Dispersion stabilizing resin                                                   Acrylic resin A                                                                              143    143                                                       Alkyd resin B                                                                  Alkyd resin C                 143    143                                       Particle/resin                                                                               70/30  70/30    70/30  70/30                                     Water separation step                                                          Amine salt of organic acid                                                                   Acetic Acetic   Formic Formic acid/                              (20% aq. solution)                                                                           acid/TEA                                                                              acid/TEA acid/TMA                                                                              pyridine                                                 50     50       50     50                                       Water-washing step                                                             Deionized water                                                                              400    400      400     400                                      Amine salt of organic acid                                                                   Acetic Acetic   Formic Formic acid/                              (20% aq. solution)                                                                           acid/TEA                                                                              acid/TEA acid/TMA                                                                              pyridine                                                 25     25       25     25                                       Residual water (%)                                                                            2.5    2.7      2.8    2.9                                      Residual water removing step                                                   Method        Formamide                                                                             Sumika Gel S50                                                                          Molecular                                                                             Na.sub.2 SO.sub.4                                        47     10      sieve  164                                                                     4Al/8                                                                          20                                               Desolvation step                                                               Amount of xylene added                                                         Amount of desolvation                                                                        171    171      171    171                                       Characteristics of polymer non-aqueous dispersion                              Non-volatile matter (%)                                                                      50.2   50.4     50.0   50.1                                      Viscosity (cps)                                                                              357    523      395    466                                       Average particle dia. (nm)                                                                   295    684      342    320                                       Water content (%)                                                                             0.2    0.2      0.3    0.2                                      Total ionic group concen-                                                                    1.03 × 10.sup.-5                                                                0.87 × 10.sup.-5                                                                  0.79 × 10.sup.-5                                                                0.84 × 10.sup.-5                    tration of polymer                                                             particles (mol./g particle)                                                    Na ion concentration (ppm)                                                                    29     31       28     27                                       __________________________________________________________________________

Manufacturing Example A31 Manufacture of Polymer Aqueous Dispersion (Comparative Manufacturing Example)

    ______________________________________                                         Aerosol 18 (trade name of di-sodium N-octadecyl-                                                         3.00    parts                                        sulpho-succinate, manufactured by American                                     Cyanamid)                                                                      Aerosol AY65 (trade name of sodium                                                                       1.50     "                                           diamyl-sulpho-succinate, manufactured by                                       American Cyanamid)                                                             Sodium bicarbonate        0.25     "                                           Deionized water (No. 1)   39.75    "                                           Ammonium persulphate      0.25     "                                           Deionized water (No. 2)   7.25     "                                           Styrene                   11.975   "                                           Butyl methacrylate        11.050   "                                           2-Ethylhexyl acrylate     9.125    "                                           2-Hydroxypropyl methacrylate                                                                             11.050   "                                           Acrylic acid              0.95     "                                           Trimethylolpropane triacrylate                                                                           3.85     "                                           ______________________________________                                    

A 5 l five-necked flask equipped with a reflux condenser, a thermometer and a stirrer was charged with Aerosol 18, Aerosol AY65, sodium bicarbonate, and the deionized water (No. 1). Ammonium persulphate and the deionized water (No. 2) were premixed and put into a small adding funnel. Styrene, butyl methacrylate, 2-ethylhexyl acrylate, 2-hydroxypropyl methacrylate, acrylic acid and trimethylol propane triacrylate were premixed and put into another adding funnel. An anionic surfactant and water were mixed and heated up to 87°±2° C. when 10% of the ammonium persulphate solution was added. The α,β-ethylenically unsaturated monomers were continuously introduced into the flask taking 2 hours and 30 minutes. At the same time, the rest of the ammonium persulphate solution was continuously added taking 3 hours. After the addition of the ammonium persulphate solution, polymer aqueous dispersion A31 was cooled down to room temperature and taken out. This dispersion had 48.2% non-volatile matter and an average particle diameter of 153 nm.

Additionally, this dispersion A31 was diluted with deionized water to reduce the non-volatile matter to 20% and analyzed by exactly the same method as described in Manufacturing Example A1, (i) and (ii). Hexane tolerance and degree of swelling in acetone were determined as follows:

HT=7

S=3.5

Manufacturing Example B33 Manufacture of Polymer Non-Aqueous Dispersion (Comparative Manufacturing Example)

    ______________________________________                                               n-Butyl alcohol         17.60 parts                                            Ethylene glycol monoethylether acetate                                                                 17.60 parts                                            Polymer aqueous dispersion A31                                                                         11.37 parts                                            t-Butyl-2-ethyl hexanoate (50% solution                                                                0.71 parts                                             in mineral spirit)                                                       (Premix I)                                                                           Styrene                 13.34 parts                                            Butyl methacrylate      11.50 parts                                            n-Dodecyl mercaptan     1.70 parts                                       (Premix II)                                                                          2-Ethylhexyl acrylate   10.76 parts                                            2-Hydroxyethyl acrylate 9.25 parts                                             Acrylic acid            0.97 parts                                             t-Butyl-2-ethyl hexanoate (50% solution                                                                4.54 parts                                             in mineral spirit)                                                             t-Butyl-2-ethyl hexanoate (50% solution                                                                0.23 parts                                             in mineral spirit)                                                             Ethylene glycol monoethylether acetate                                                                 0.43 parts                                       ______________________________________                                    

A four-necked-flask equipped with a reflux condenser, a Dean & Stark apparatus, a thermometer and a stirrer was charged with n-butyl alcohol, ethylene glycol monoethylether acetate, polymer aqueous dispersion and t-butyl-2-ethyl hexanoate. Styrene, butyl methacrylate and n-dodecyl mercaptan were premixed and put into an adding funnel (Premix I).

2-Ethylhexyl acrylate, 2-hydroxyethyl acrylate, acrylic acid and the second t-butyl-2-ethyl hexanoate were premixed and put into a second funnel (Premix II).

The solvents, polymer aqueous dispersion and t-butyl 2-ethyl hexanoate were heated to 95° C. and refluxed. Thereafter, Premixes I and II were added concurrently and continuously taking 4 hours. While the α,β-ethylenically unsaturated monomers were added, water was separated by azeotropic distillation from the polymer aqueous dispersion and removed continuously through the Dean & Stark apparatus. Immediately after the addition of Premixes I and II, a mixture of t-butyl 2-ethyl hexanoate and ethylene glycol monoethylether acetate was added taking 1 hour. After refluxing until the theoretical amount of water had been completely removed, polymer non-aqueous dispersion B33 was obtained by cooling. This polymer non-aqueous dispersion B33 contained 11% polymer particles based on the total non-volatile matter with resins and had characteristics of an average particle diameter of 170 nm, 56.2% non-volatile matter, a viscosity of T and an acid value of 17.5.

Further, this dispersion B33 was analyzed by the same method as described in Manufacturing Example B1, (i) and (ii), and the following total ionic group concentration in polymer particle (I) and Na ion concentrations in dispersion were determined.

    I=I.sub.1 +I.sub.2 =4.58×10.sup.-4 mol/g particle

wherein

I₁ is carboxylate ion concentration, i.e., 3.13×10⁻⁴ mol/g particle, and

I₂ is the sum of sulphonate and sulphate ion concentrations, i.e., 1.45×10⁻⁴ mol/g particle.

    Na ion concentration=292 ppm

The carboxylate ion concentration I₁ of polymer particle determined here is equivalent to 98.1 mol % of total carboxylate ion concentration contained in the acrylic acid and Aerosol 18 formulated during the emulsion polymerization. Alternatively, the sum of sulphonate and sulphate ion concentrations I₂ is equivalent to 99.1 mol % of the sum of sulphonate and sulphate ion concentrations contained in fragments of Aerosol 18, Aerosol AY65 and ammonium persulphate formulated during the emulsion polymerization.

Alternatively, the Na ion concentration is equivalent to 99.6 mol % of total amount of Na ions in Aerosol 18, Aerosol AY65 and sodium bicarbonate formulated during the emulsion polymerization.

Manufacturing Example B34 Manufacture of Polymer Non-Aqueous Dispersion (Comparative Manufacturing Example)

To 20 parts of the polymer aqueous dispersion prepared in Manufacturing Example A31, 40 parts of acetone were added to aggregate polymer particles and a suspension was obtained. Sixty parts of this suspension were centrifugalized at 15,000 rpm for 1 hour to separate into supernatant and precipitate. To the precipitate, 40 parts of acetone were further added. After stirring thoroughly, the centrifugation was conducted again in the same manner as the above to separate into cleaning solution and precipitate. This procedure was repeated 5 times to wash the precipitate with acetone. The supernatants were all mixed together and anionic surfactants dissolved therein were quantitatively analyzed by Weatherburn process. As a result, anionic surfactants equivalent to 29 mol % of the total amount of Aerosol 18 and Aerosol AY65 used in Manufacturing Example A31 were detected in the supernatants. Namely, it proved that anionic surfactants equivalent to 71 mol % of the total amount of used surfactants remained in the polymer particles.

The precipitate was dried under a reduced pressure, then added to 38.4 parts of ethyl acetate and stirred with a stirrer to disperse therein to provide polymer non-aqueous dispersion B34 having 20% non-volatile matter.

Further, this dispersion B34 was analyzed by the same method as described in Manufacturing Example B1, (i) and (ii), and the following total ionic group concentrations (I) in polymer particle and Na ion concentrations in dispersion were determined.

    I=I.sub.1 +I.sub.2 =4.12×10.sup.-4 mol/g particle

wherein

I₁ is carboxylate ion concentration, i.e., 3.08×10⁻⁴ mol/g particle, and

I₂ is the sum of sulphonate and sulphate ion concentrations, i.e., 1.16×10⁻⁴ mol/g particle.

    Na ion concentration=150 ppm

The carboxylate ion concentration I₁ of polymer particle determined here is equivalent to 95.6 mol % of total carboxylate ion concentration contained in the acrylic acid and Aerosol 18 formulated during the emulsion polymerization.

Alternatively, the sum of sulphonate and sulphate ion concentrations I₂ is equivalent to 79.4 mol % of the sum of sulphonate and sulphate ion concentrations contained in fragments of Aerosol 18, Aerosol AY65 and ammonium persulphate formulated during the emulsion polymerization.

Alternatively, the Na ion concentration is equivalent to 51.1 mol % of total amount of Na ions in Aerosol 18, Aerosol AY65 and sodium bicarbonate formulated during the emulsion polymerization.

Manufacturing Example B35 Manufacture of Polymer Non-Aqueous Dispersion (Comparative Manufacturing Example)

(a) Manufacture of α,β-ethylenically unsaturated monomers,

A four-necked flask equipped with stirrer, a thermometer, a Dean & Stark apparatus provided with a reflux condenser and a nitrogen gas feed pipe, was charged with 1,500 parts of 12-hydroxystearic acid and heated to raise the temperature up to 200° C. while stirring, as feeding nitrogen gas. When the acid value reached 39, the reaction was stopped. After the reactants was left to cool, 159 parts of xylene were added and a 12-hydroxystearic acid 5 mole condensate solution having 90% non-volatile matter was obtained. In this reaction 72 parts of water were separated. Then, using this 12-hydroxystearic acid 5 mole condensate solution, a mixture having the below-noted composition was stirred at a temperature of 120° C. in a four-necked flask equipped with a stirrer, a thermometer, a reflux condenser and a nitrogen gas feed pipe, to undergo an esterification reaction until acid value of non-volatile matter became below 1.0 and an α,β-ethylenically unsaturated monomer having 80% non-volatile matter was obtained.

    ______________________________________                                         12-Hydroxystearic acid 5 mole condensate solution                                                        1,586.67 parts                                       Glycidyl methacrylate     142.00 parts                                         N,N-dimethyl benzylamine  3.93 parts                                           Hydroquinone              1.96 parts                                           Xylene                    227.94 parts                                         ______________________________________                                    

(b) Manufacture of Amphipathic Dispersion Stabilizer.

A four-necked flask equipped with a stirrer, a reflux condenser, a thermometer and a dropping funnel was charged with 405.0 parts of ethyl acetate and 203.4 parts of n-butyl acetate and refluxed while stirring. Then, during refluxing, a mixture having the below-noted composition was added at a constant adding rate taking 3 hours and, by further refluxing for 2 hours, an amphipathic dispersion stabilizer having 33% non-volatile matter was obtained.

    ______________________________________                                         α,β-ethylenically unsaturated monomer solution                                                275.0 parts                                          prepared in the aforementioned item (a)                                        Methyl methacrylate       104.5 parts                                          Acrylic acid              5.5 parts                                            Azo-di-isobutyronitrile   6.6 parts                                            ______________________________________                                    

(c) Manufacture of Polymer Non-Aqueous Dispersion.

A four-necked flask equipped with a stirrer, a thermometer, a reflux condenser and a device for adding a liquid feed to returning condensates, was charged with a mixture having the below-noted composition.

    ______________________________________                                         Mineral spirit            1,588.0 parts                                        Hexane                    389.0 parts                                          Heptane                   2,080.2 parts                                        Methyl methacrylate       236.4 parts                                          Azo-di-isobutyronitrile   18.7 parts                                           Amphipathic dispersion stabilizer solution prepared                                                      88.1 parts                                           in the aforementioned item (b)                                                 ______________________________________                                    

The above contents were heated to 100° C. and kept under refluxing for 1 hours. Then the under-noted components were premixed and added at a constant adding rate to hydrocarbons returning from the condenser, taking 6 hours.

    ______________________________________                                         Methyl methacrylate       4,491.8 parts                                        Methacrylic acid          45.8 parts                                           Glycidyl methacrylate     45.8 parts                                           Azo-di-isobutyronitrile   60.2 parts                                           Amphipathic dispersion stabilizer solution prepared                                                      945.3 parts                                          in the aforementioned item (b)                                                 ______________________________________                                    

However, for 1 hour at the last stage of the addition, 3.3 parts of triethylene diamine were additionally mixed in the above-mentioned mixture. After completion of the addition, the reaction mixture was kept under refluxing for 3 hours to provide polymer non-aqueous dispersion having 52% non-volatile matter and containing 31.2% polymer particles having an average particle diameter of 200 nm.

(d) Modification with Auxiliary Polymer of Particles.

A four-necked flask equipped with the devices used in the above step (c) was charged with the under-noted components and heated up to a refluxing temperature (115° C.).

    ______________________________________                                         Polymer non-aqueous dispersion                                                                        4,747.1 parts                                           prepared in the above item (c)                                                 Ethyl cyclohexane      1,638.2 parts                                           ______________________________________                                    

Then, the under-noted components were premixed and added at a constant adding rate to hydrocarbons returning from the condenser, taking 3 hours.

    ______________________________________                                         Methyl methacrylate       334.2 parts                                          2-Hydroxyethyl methacrylate                                                                              190.6 parts                                          Methacrylic acid          49.6 parts                                           Butyl methacrylate        369.1 parts                                          2-Ethylhexyl acrylate     381.2 parts                                          Styrene                   571.2 parts                                          t-Butyl peroxybenzoate    90.6 parts                                           Octyl mercaptan           84.7 parts                                           Amphipathic dispersion stabilizer solution prepared                                                      149.5 parts                                          in the aforementioned item (b)                                                 ______________________________________                                    

After completion of the addition, the reaction mixture was refluxed for 2 hours. Then the following solvent mixture was added to obtain polymer non-aqueous dispersion B35 having 45% non-volatile matter and containing 25% polymer particles.

    ______________________________________                                         n-Butyl alcohol      559.0 parts                                               Xylene               372.3 parts                                               Butyl acetate        462.7 parts                                               ______________________________________                                    

EXAMPLES 1˜8 Application to 2 Coat·1 Bake Solids

(A) Manufacture of Base Coat Paints (Examples 1˜8).

Using the obtained polymer non-aqueous dispersions B1˜B8, components excepting melamine resin in the formulations shown in Table 8 were fed into a paint shaker and dispersed until the particle size became 10 μm or less. Then, the melamine resin shown in Table 8 was added to prepare paints.

(B) Manufacture of clear coatings (Examples 1˜4).

Mixtures having compositions shown in Table 9 were stirred to prepare clear coatings.

(C) Manufacture of tinted clear coatings. (Examples 5˜7).

Components excepting melamine resin in the formulations shown in Table 10 were fed into a paint shaker and dispersed until the particle size became 10 μm or less. Then, the melamine resin shown in Table 10 was added to prepare coatings.

                                      TABLE 8                                      __________________________________________________________________________     Unit: part                                                                                Example                                                                        1(A)                                                                              2(A)                                                                              3(A)                                                                              4(A)                                                                              5(A)                                                                              6(A)                                                                               7(A)                                                                              8(A)                                          __________________________________________________________________________     Polymer    B1 B2 B3 B4 B5 B6  B7 B8                                            non-aqueous                                                                               14.3                                                                              14.3                                                                              28.6                                                                              28.6                                                                              57.2                                                                              57.2                                                                               28.6                                                                              42.9                                          dispersion                                                                     Acrylic resin (1) (2)                                                                     A  A  A  A  B  B   B  B                                                        96.4                                                                              96.4                                                                              84.5                                                                              84.5                                                                              60.7                                                                              60.7                                                                               84.5                                                                              72.6                                          Melamine resin (3)                                                                        35 35 35 35 35 35  35 35                                            Quinacridone (4)                                                                          36 36 36 36 36 36  36 36                                            Red iron oxide (5)                                                                        4  4  4  4  4  4   4  4                                             PTSA solution (6)                                                                         1.5                                                                               1.5                                                                               1.5                                                                               1.5                                                                               1.5                                                                               1.5 1.5                                                                               1.5                                           Xylene     16 16 16 16 16 16  16 16                                            n-Butyl alcohol                                                                           4  4  4  4  4  4   4  4                                             __________________________________________________________________________      (1) Acrylic resin A: same as the acrylic resin on the footnote of Table 5      (2) Acrylic resin B: same as the acrylic resin on the footnote of Table 6      (3) Resimene 755 (trade name of a methyl/butyl mixetherified melamine          resin having 100% heating residue, manufactured by Monsanto.                   (4) Rubicron Red 500RG (trade name of quinacridone, manufactured by Toyo       Soda Manufacturing Co., Ltd.).                                                 (5) KNR (trade name of red iron oxide, manufactured by Toda Kogyo              Corporation).                                                                  (6) PTSA solution: ptoluene sulphonic acid 20% isopropylalcohol solution.

                  TABLE 9                                                          ______________________________________                                         Unit: part                                                                                      Example                                                                        1(B) 2(B)    3(B)   4(B)                                      ______________________________________                                         Polymer non-aqueous dispersion                                                                    B1     B2      B3   B4                                                         14.3   14.3    28.6 28.6                                    Acrylic resin (1)  A      A       A    A                                                          96.4   96.4    84.5 84.5                                    Melamine resin (2) 35     35      35   35                                      PTSA solution (3)  1.5    1.5     1.5  1.5                                     Xylene             8      8       8    8                                       n-Butyl alcohol    2      2       2    2                                       ______________________________________                                          (1)˜(3): same as the footnotes of Table 8.                         

                  TABLE 10                                                         ______________________________________                                         Unit: part                                                                                      Example                                                                        5(C) 6(C)    7(C)   8(C)                                      ______________________________________                                         Polymer non-aqueous dispersion                                                                    B5     B6      B7   B8                                                         28.6   57.2    14.3 28.6                                    Acrylic resin (1)  B      B       B    B                                                          84.5   60.7    96.4 84.5                                    Melamine resin (2) 35     35      35   35                                      Quinacridone (3)   2      2       2    2                                       PTSA solution (4)  1.5    1.5     1.5  1.5                                     Xylene             8      8       8    8                                       n-Butyl alcohol    2      2       2    2                                       ______________________________________                                          (1)˜(4): same as the footnotes of Table 8.                         

(D) Preparation of coating films.

With respect to the coatings having compositions shown in Tables 8, 9 and 10, the base coat paints were diluted to viscosity for coating (14 seconds at 20° C. with Ford cup No. 4) with a thinner of toluene/n-butyl alcohol=8/2 (weight ratio), and the clear coatings and tinted clear coatings were diluted to viscosity for coating (30 seconds at 20° C. with Ford cup No. 4) with a thinner of xylene/n-butyl alcohol=9/1 (weight ratio). Then, onto a zinc phosphate treated mild steel sheet, a cationic electrocoating, Aqua No. 4200 (trade name, manufactured by Nippon Oil & Fats Co., Ltd.), was electrocoated so as to yield a dry film thickness of 20 μm and baked at 175° C. for 25 minutes. Further, a test sheet on which a sealer, Epico No. 1500 sealer (trade name, manufactured by Nippon Oil & Fats Co., Ltd.), was spray-coated so as to yield a dry film thickness of 40 μm followed by baking at 140° C. for 30 minutes, was air-spray-coated with the above diluted clear and tinted clear coatings and baked at 140° C. for 30 minutes in a vertical position. No saggings observed until the film thicknesses shown in Table 14, coating films having excellent appearance and quality as the coating film appearance values shown in Table 14 were obtained.

Further, after these coating films were soaked in hot water at 95° C. for 4 hours, none of blisters and discoloration were observed. After leaving the films to stand at 20° C. for 2 hours after the soaking, eleven parallel cross-cut lines at 2 mm spaces with a depth to reach the substrate were drawn with a knife to form square chequers on the coating films. A cellophane adhesive tape was adhered closely onto the chequers. When the adhesive tape was peeled off upwards at a stretch, no peeling of coating films was observed and the films exhibited excellent water resistance and adhesion.

Alternatively, an accelerated weathering test carried out for 1,500 hours with a sunshine weatherometer caused no cracks or blisters on any films, providing excellent weatherability.

EXAMPLES 9˜15 Application to 2 Coat·1 Bake Metallic

(A) Manufacture of base coat paints (Examples 9˜15).

Using the polymer non-aqueous dispersions prepared in Manufacturing Examples B9˜B15, coating compositions were manufactured with the formulations shown in Table 11 and diluted to viscosity for coating (14 seconds at 20° C. with Ford cup No. 4) with a thinner (toluene/n-butyl alcohol=8/2 by weight ratio).

(B) Manufacture of clear coatings (Examples 9˜15)

Using the polymer non-aqueous dispersions prepared in Manufacturing Examples B9˜B15, coating compositions were manufactured with the formulations shown in Table 12 and diluted to viscosity for coating (30 seconds at 20° C. with Ford cup No. 4) with a thinner (xylene/n-butyl alcohol=9/1 by weight ratio).

                                      TABLE 11                                     __________________________________________________________________________     Unit: part                                                                                Example                                                                        9(A)                                                                              10(A)                                                                              11(A)                                                                              12(A)                                                                              13(A)                                                                              14(A)                                                                              15(A)                                        __________________________________________________________________________     Polymer    B9 B10 B11 B12 B13 B14 B15                                          non-aqueous                                                                               57.2                                                                              57.2                                                                               57.2                                                                               57.2                                                                               57.2                                                                               57.2                                                                               57.2                                         dispersion                                                                     Acrylic resin 1)                                                                          A  A   A   A   A   A   A                                                       60.7                                                                              60.7                                                                               60.7                                                                               66.6                                                                               66.6                                                                               50  50                                           Melamine resin 2)                                                                         35 35  35  31.4                                                                               31.4                                                                               41.4                                                                               41.4                                         Aluminum pigment 3)                                                                       15.4                                                                              15.4                                                                               15.4                                                                               15.4                                                                               15.4                                                                               15.4                                                                               15.4                                         PTSA solution 4)                                                                           1.5                                                                               1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                         Xylene     8  8   8   8   8   8   8                                            n-Butyl alcohol                                                                           2  2   2   2   2   2   2                                            __________________________________________________________________________      1), 2), 4): same as the footnotes of Table 8.                                  3): Alpaste 7160N (trade name of aluminum pigment manufactured by Toyo         Aluminium K.K.; nonvolatile matter, 65%)                                 

                                      TABLE 12                                     __________________________________________________________________________     Unit: part                                                                                Example                                                                        9(B)                                                                              10(B)                                                                              11(B)                                                                              12(B)                                                                              13(B)                                                                              14(B)                                                                              15(B)                                        __________________________________________________________________________     Polymer    B9 B10 B11 B12 B13 B14 B15                                          non-aqueous                                                                               14.3                                                                              14.3                                                                               14.3                                                                               28.6                                                                               28.6                                                                               42.9                                                                               42.9                                         dispersion                                                                     Acrylic resin 1)                                                                          A  A   A   A   A   A   A                                                       96.4                                                                              96.4                                                                               96.4                                                                               91.7                                                                               91.7                                                                               83.3                                                                               83.3                                         Melamine resin 2)                                                                         35 35  35  30.7                                                                               30.7                                                                               28.6                                                                               28.6                                         PTSA solution 3)                                                                           1.5                                                                               1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                         Xylene     8  8   8   8   8   8   8                                            n-Butyl alcohol                                                                           2  2   2   2   2   2   2                                            __________________________________________________________________________      1)˜3): same as the footnotes of Table 8.                           

(C) Preparation of coating films.

Onto test sheets on which an electrocoated film and an intermediate coat were formed in the same manner as those in Examples 1˜8, diluted base coat paints were air-spray-coated in two stages at an interval of 1 minute 30 seconds so as to yield a dry film thickness of 15 μm followed by setting at 20° C. for 3 minutes. Then, diluted clear coatings were air-spray-coated and test sheets were prepared in the same manner as those in Examples 1˜8. All of the resulting coating films had no metallic marks thereon and were excellent in appearance and quality, sag limit film thickness, water resistance, adhesion and weatherability as shown in Table 14.

EXAMPLES 16˜22 Application to 1 Coat Solids

(A) Manufacture of coating compositions.

Using the polymer non-aqueous dispersions prepared in Manufacturing Examples B17˜B20 and B22˜B24, components excepting curing agent in the formulations shown in Table 13 were fed into a paint shaker and dispersed until the particle size became 10 μm or less. In Examples 16˜18, two component coatings were manufactured and in Examples 19˜22, further adding a curing agent and stirring, one component coating was manufactured.

                                      TABLE 13                                     __________________________________________________________________________                     Example                                                                        16 (D) 17 (D) 18 (D) 19 (D) 20 (D) 21 (D)                                                                               22                    __________________________________________________________________________                                                              (D)                   Polymer non-aqueous dispersion                                                                 B 17   B 18   B 19   B 20   B 22   B 23  B 24                                    14.3   14.3   14.3   14.3   14.3   14.3                                                                                 14.3                Alkyd resin C 1)                                                                                 99.8   99.8   99.8   96.4   96.4   96.4                                                                               100                   Curing agent 2) Coronate EH                                                                           Coronate EH                                                                           Coronate EH                                                                           Resimene 755                                                                          Resimene 755                                                                          Cymel                                                                                Cymel 1171                            33     33     33     35     35     35      36.5                Quinacridone 3)                      15     15     15    15                    Red iron oxide 4)                    15     15     15    15                    Phthalocyanine Blue 5)                                                                         15     15     15                                               Titanium dioxide 6)                                                                            15     15     15                                               PTSA solution 7)                       1.5    1.5    1.5   1.5                 Xylene          16     16     16     16     16     16    16                    Butyl acetate    2      2      2      2      2      2     2                    __________________________________________________________________________      (1) Alkyd resin C: same as the alkyd resin shown in the footnotes of Tabl      6.                                                                             (2) Curing agent: Coronate EH: trade name of hexamethylene diisocyanate        trimer, manufactured by Nippon Polyurethane Industry Co. (21% isocyanate       group, and 100% nonvolatile matter). Resimene 755: as aforenoted. Cymel        303: trade name of methylated melamine resin manufactured by American          Cyanamid; 100% nonvolatile matter. Cymel 1171: as aforenoted.                  (3) Rubicron Red 500 RG: as aforenoted.                                        (4) KNR: as aforenoted.                                                        (5) Fastgen Blue RGA: trade name of phthalocyanine blue manufactured by        Dainippon Ink & Chemicals, Incorporated.                                       (6) JR602: trade name of titanium dioxide, manufactured by Teikoku Kako        Co., Ltd.                                                                

(B) Preparation of coating films.

Coating compositions having the formulations shown in Table 13 were diluted to viscosity for coating (30 seconds at 20° C. with Ford cup No. 4) with a thinner (xylene/ethylene glycol monoethylether acetate=9/1 by weight ratio). Meanwhile, with respect to Examples 16˜18, Coronate EH was admixed immediately before the dilution.

Then, test sheets on which an electrocoated film and an intermediate coat were formed were air-spray-coated in the same manner as those in Examples 1˜8, followed by drying in the same manner as those in Examples 1˜8, to obtain coating films excellent in appearance and quality, sag limit film thickness, water resistance, adhesion and weatherability as shown in Table 15.

                                      TABLE 14(a)                                  __________________________________________________________________________      Unit: part                                                                    __________________________________________________________________________                     Example                                                                        1      2      3      4      5                                  __________________________________________________________________________     Coating system  2 coat · 1 take solids                                Coating color   Red                                                            Form of clear   Clear                       Tinted clear                       Coating composition                                                            Base coat       1(A)   2(A)   3(A)   4(A)   5(A)                               Clear coat      1(B)   2(B)   3(B)   4(B)   5(C)                               Binder 1)                                                                      Base coat                                                                      Polyol resin 2) A      A      A      A      B                                                  63     63     61     61     56                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       37     37     39     39     44                                 Polymer particles                                                                              B1     B2     B3     B4     B5                                                  5.3    5.3   11.1   11.1   25.0                               Clear                                                                          Polyol resin 2) A      A      A      A      B                                                  63     63     61     61     61                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       37     37     39     39     39                                 Polymer particles                                                                              B1     B2     B3     B4     B5                                                  5.3    5.3   11.1   11.1   11.1                               appearance of coating film                                                     20° gloss                                                                               85     83     82     83     84                                 D/I value 3)    90     89     91     88     91                                 Sag limit film thickness (μm) 4)                                                            44     44     47     47     47                                 Film performance                                                               Water resistance                                                                               No     No     No     No     No                                 (95° C. × after 4 hours) 5)                                                       abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        Adhesion        100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                               100/100                            (after water resistance test) 6)                                               Weatherability (1,500 hours                                                                    No     No     No     No     No                                 with sunshine weatherometer) 7)                                                                abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        __________________________________________________________________________                     Example                                                                        6      7      8      9      10                                 __________________________________________________________________________     Coating system  2 coat · 1 bake solids                                                                     2 coat · 1 bake metallic         Coating color   Red                  Silver                                    Form of clear   Tinted clear         Clear                                     Coating composition                                                            Base coat       6(A)   7(A)   8(A)   9(A)   10(A)                              Clear coat      6(C)   7(C)   8(C)   9(B)   10(B)                              Binder 1)                                                                      Base coat                                                                      Polyol resin 2) B      B      B      A      A                                                  56     61     59     55     56                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       44     39     41     44     44                                 Polymer particles                                                                              B6     B7     B8     B9     B10                                                25.0   11.1   17.6   25.0   25.0                               Clear                                                                          Polyol resin 2) B      B      B      A      A                                                  56     63     61     63     63                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       44     37     39     37     37                                 Polymer particles                                                                              B6     B7     B8     B9     B10                                                25.0    5.3   11.1    5.3    5.3                               appearance of coating film                                                     20° gloss                                                                               85     86     85     85     84                                 D/I value 3)    91     90     89     90     88                                 Sag limit film thickness (μm) 4)                                                            50     44     48     50     50                                 Film performance                                                               Water resistance                                                                               No     No     No     No     No                                 (95° C. × after 4 hours) 5)                                                       abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        Adhesion        100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                               100/100                            (after water resistance test) 6)                                               Weatherability (1,500 hours                                                                    oN     No     No     No     No                                 with sunshine weatherometer) 7)                                                                abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        __________________________________________________________________________                     Example                                                                        11     12     13     14     15                                 __________________________________________________________________________     Coating system  2 coat · 1 bake metallic                              Coating color   Silver                                                         Form of clear   Clear                                                          Coating composition                                                            Base coat       11(A)  12(A)  13(A)  14(A)  15(A)                              Clear coat      11(B)  12(B)  13(B)  14(B)  15(B)                              Binder 1)                                                                      Base coat                                                                      Polyol resin 2) A      A      A      A      A                                                  56     50     50     38     38                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       44     50     50     62     62                                 Polymer particles                                                                              B11    B12    B13    B14    B15                                                25.0   25.0   25.0   25.0   25.0                               Clear                                                                          Polyol resin 2) A      A      A      A      A                                                  63     61     61     59     59                                 Curing agent    Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                       37     39     39     41     41                                 Polymer particles                                                                              B11    B12    B13    B14    B15                                                 5.3   11.1   11.1   17.6   17.6                               appearance of coating film                                                     20° gloss                                                                               85     86     83     82     83                                 D/I value 3)    91     89     88     90     89                                 Sag limit film thickness (μm) 4)                                                            51     52     52     54     54                                 Film performance                                                               Water resistance                                                                               No     No     No     No     No                                 (95° C. × after 4 hours) 5)                                                       abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        Adhesion        100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                               100/100                            (after water resistance test) 6)                                               Weatherability (1,500 hours                                                                    No     No     No     No     No                                 with sunshine weatherometer) 7)                                                                abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                                                                           abnormality                        __________________________________________________________________________      1) Calculated as solid matter.                                                 2) Polyol resin:                                                               A: acrylic resin A, and                                                        B: acrylic resin B.                                                            3) D/I value: a value representing sharpness of coating films (determined      by Hunterlab Dorigon Model D47R6F Glossmetr).                                  4) Sag limit film thickness: a maximal film thickness right before clear       films start to sag.                                                            5) No abnormality in water resistance: none of blisters and discoloration      were observed on coating films.                                                6) Adhesion: 100/100 means no peeling was observed.                            7) Weatherability: determined in accordance with JIS D 0205 7.6,               Accelerated Weathering Testing Method (with sunshine carbon                    weatherometer).                                                                No abnormality in weatherability: none of cracks and blisters were             observed on coating films.                                               

                                      TABLE 15                                     __________________________________________________________________________     Unit: part                                                                                   Example                                                                          16     17     18     19     20     21    22                    __________________________________________________________________________     Coating system  1 coat solids                                                  Coating color   Blue                 Red                                       Coating composition                                                                            16(D)  17(D)  18(D)  19(D)  20(D)  21(D) 22(D)                 Binder (1)                                                                     Polyol resin 2) C      C      C      C      C      C     C                                     65     65     65     63     63     63    63                    Curing agent    Coronate EH                                                                           Coronate EH                                                                           Coronate EH                                                                           Resimene 755                                                                          Resimene 755                                                                          Cymel                                                                                Cymel 1171                            35     35     35     37     37     37    37                    Polymer particles                                                                              B17    B18    B19    B20    B22    B23   B24                                     5.3    5.3    5.3    5.3    5.3    5.3   5.3                 Appearance of coating film                                                     20° gloss                                                                               84     83     82     83     85     84    84                    D/I value 3)    90     91     92     91     90     89    91                    Sag limit film thickness (μm) 4)                                                            50     50     51     50     54     55    54                    Film performance                                                               Water resistance                                                                               No     No     No     No     No     No    No                    (95° C. × after                                                                   abnor- abnor- abnor- abnor- abnor- abnor-                                                                               abnor-                4 hours) 5)     mality mality mality mality mality mality                                                                               mality                Adhesion (after 100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                               100/100                                                                              100/100               water resistance                                                               test) 6)                                                                       Weatherability  No     No     No     No     No     No    No                    (1,500 hours with                                                                              abnor- abnor- abnor- abnor- abnor- abnor-                                                                               abnor-                sunshine        mality mality mality mality mality mality                                                                               mality                weatherometer) 7)                                                              __________________________________________________________________________      1) Calculated as solid matter.                                                 2) Polyol resin C: alkyd resin C.                                              3) D/I value: a value representing sharpness of coating films (determined      by Hunterlab Dorigon Model D47R6F Glossmeter).                                 4) Sag limit film thickness: a maximal film thickness right before clear       films started to sag.                                                          5) No abnormality in water resistance: non of blisters and discoloration       were observed on coating films.                                                6) Adhesion: 100/100 means no peeling was observed.                            7) Weatherability: determined in accordance with JIS D 0205 7.6,               Accelerated Weathering Testing Method (with sunshine carbon                    weatherometer). No abnormality in weatherability: none of cracks and           blisters were observed on coating film.                                  

EXAMPLES 23˜26 Application to 2 Coat.1 Bake Solids

Based on the formulations shown in Table 16, base coat and tinted clear coatings were manufactured in the same manner as that in Example 5 and 2 coat.1 bake solid coating films were prepared following the procedure in Example 5. The appearance and property, sag limit film thickness and performance of coating films are all together shown in Table 17.

All of these coating films had excellent qualities, inter alia, the polymer particles in Example 24 which had hydroxyl terminal groups on chain segments extending outwards from surfaces thereof, and the polymer particles in Example 25 which had a core-shell structure, exhibited particularly excellent sag limit film thicknesses and weatherability. Additionally, the polymer particles in Example 26 had a core-shell structure and hydroxyl terminal groups on chain segments extending outwards from surfaces thereof, so that they exhibited the highest quality among others in sag limit film thickness and weatherability.

                                      TABLE 16                                     __________________________________________________________________________     Unit: part                                                                                     Example                                                                        23(A)                                                                              23(C)                                                                              24(A)                                                                              24(C)                                                                              25(A)                                                                              25(C)                                                                              26(A)                                                                              26(C)                                              Base                                                                               Tinted                                                                             Base                                                                               Tinted                                                                             Base                                                                               Tinted                                                                             Base                                                                               Tinted                                             coat                                                                               clear                                                                              coat                                                                               clear                                                                              coat                                                                               clear                                                                              coat                                                                               clear                              __________________________________________________________________________     Polymer non-aqueous dispersion                                                                 B5  B5  B12 B12 B16 B16 B21 B21                                                  28.6                                                                              14.3                                                                              28.6                                                                                14.3                                                                                28.6                                                                              14.3                                                                                28.6                                                                              14.3                              Acrylic resin 1)                                                                               B   B   B   B   B   B   B   B                                                    84.5                                                                              96.4                                                                              91.7                                                                               100   84.5                                                                              96.4                                                                                84.5                                                                              96.4                              Melamine resin 2)                                                                              35  35  30.7                                                                                32.9                                                                              35  35  35  35                                 Quinacridone 3) 36  2   36  2   36  2   36  2                                  Red iron oxide 4)                                                                               4      4        4       4                                     PTSA solution 5)                                                                                 1.5                                                                                1.5                                                                               1.5                                                                                 1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                              Xylene          16  8   16  8   16  8   16  8                                  n-Butyl alcohol  4  2   4   2    4  2    4  2                                  __________________________________________________________________________      1)˜5) same as the footnotes of Table 8                             

                                      TABLE 17                                     __________________________________________________________________________     Unit: part                                                                                     Example                                                                        23    24    25    26                                           __________________________________________________________________________     Coating system  2 coat . 1 bake solids                                         Coating color   Red                                                            Form of clear   Tinted clear                                                   Coating composition                                                            Base coat       23(A) 24(A) 25(A) 26(A)                                        Clear coat      23(C) 24(C) 25(C) 26(C)                                        Binder 1)                                                                      Base coat                                                                      Polyol resin    Acrylic resin B                                                                61                                                             Curing agent    Resimene 755                                                                   39                                                             Polymer particles                                                                              B5    B12   B16   B21                                                          11.1  11.1  11.1  11.1                                         Tinted clear                                                                   Polyol resin    Acrylic resin B                                                                63                                                             Curing agent    Resimene 755                                                                   37                                                             Polymer particles                                                                              B5    B12   B16   B21                                                          5.3   5.3   5.3   5.3                                          Appearance of coating film                                                     20° gloss                                                                               84    85    85    86                                           D/I value 2)    91    90    91    92                                           Sag limit film thickness (μm) 3)                                                            44    50    50    54                                           Film performance                                                               Water resistance 4)                                                                            No abnor-                                                                            No abnor-                                                                            No abnor-                                                                            No abnor-                                    (95° C. × after 4 hours)                                                          mality                                                                               mality                                                                               mality                                                                               mality                                       Adhesion 5)     100/100                                                                              100/100                                                                              100/100                                                                              100/100                                      (after water resistance test)                                                  Weatherability 6)                                                                              2,600 hours                                                                          3,400 hours                                                                          3,500 hours                                                                          5,200 hours                                  (sunshine weatherometr)                                                        __________________________________________________________________________      1) Calculated as solid matter.                                                 2) D/I value: a value representing sharpness of coating films (determined      by Hunterlab Dorigon Model D47R6F Glossmeter).                                 3) Sag limit flim thickness: a maximal film thickness right before clear       films started to sag.                                                          4) No abnormality in water resistance: none of blisters and discoloration      were observed on coating films.                                                5) Adhesion: 100/100 means no peeling was observed.                            6) Time required for crack development.                                  

EXAMPLES 27˜30 Application to 2 Coat.1 Bake Solids

Based on the formulations shown in Table 18, base coat paints and clear or tinted clear coatings were manufactured, as to Examples 27 and 28, in the same manner as that in Example 1, and as to Examples 29 and 30, in the same manner as that in Example 5, and 2 coat.1 bake solid coating films were prepared following the procedure in Example 1. As shown in Table 21, coating films having excellent appearance and quality, sag limit film thickness and performance of film were obtained.

                                      TABLE 18                                     __________________________________________________________________________     Unit: part                                                                                Example                                                                        27 (A)  28 (A)  29 (A)                                                                             29 (C)                                                                             30 (A)                                                                             30 (C)                                             Base                                                                               27 (B)                                                                             Base                                                                               28 (B)                                                                             Base                                                                               Tinted                                                                             Base                                                                               Tinted                                             coat                                                                               Clear                                                                              coat                                                                               Clear                                                                              coat                                                                               clear                                                                              coat                                                                               clear                                   __________________________________________________________________________     Polymer non-aqueous                                                                       B25 B25 B26 B26 B27 B27 B28 B28                                     dispersion   28.6                                                                             14.3                                                                                 28.6                                                                             14.3                                                                                 28.6                                                                             14.3                                                                                 28.6                                                                             14.3                                    Acrylic resin.sup.1                                                                       A   A   A   A   B   B   B   B                                                    84.5                                                                             96.4                                                                                 84.5                                                                             96.4                                                                                 84.5                                                                             96.4                                                                                 84.5                                                                             96.4                                    Melamine resin.sup.2                                                                      35  35  35  35  35  35  35  35                                      Quinacridone.sup.3                                                                        36  --  36  --  36  2   36  2                                       Red iron oxide.sup.4                                                                       4  --   4  --   4  --   4  --                                      PTSA solution.sup.5                                                                         1.5                                                                               1.5                                                                                 1.5                                                                               1.5                                                                                 1.5                                                                               1.5                                                                                 1.5                                                                               1.5                                    Xylene     16  8   16  8   16  8   16  8                                       n-Butyl alcohol                                                                            4  2    4  2    4  2    4  2                                       __________________________________________________________________________      .sup.1˜5 same as the footnotes of Table 8                          

EXAMPLES 31 and 32

Based on the formulations shown in Table 19, base coat paints and clear coatings were manufactured in the same manner as that in Example 9, and 2 coat.1 bake metallic coating films were prepared following the procedure in Example 9. As shown in Table 21, coating films having excellent appearance and quality, sag limit film thickness and performance of film were obtained.

                  TABLE 19                                                         ______________________________________                                         Unit: part                                                                                Example                                                                        31 (A)          32 (A)                                                         Base   31 (B)   Base     32 (B)                                                coat   Clear    coat     Clear                                      ______________________________________                                         Polymer non-aqueous                                                                         B29      B29      B30    B30                                      dispersion   57.2     28.6     57.2   28.6                                     Acrylic resin.sup.1                                                                         A        A        A      A                                                     60.7     84.5     60.7   84.5                                     Melamine resin.sup.2                                                                        35       35       35     35                                       Aluminum pigment.sup.3                                                                      15.4     --       15.4   --                                       PTSA solution.sup.4                                                                          1.5      1.5      1.5    1.5                                     Xylene       8        8        8      8                                        n-Butyl alcohol                                                                             2        2        2      2                                        ______________________________________                                          .sup.1, 2, 4 same as the footnotes of Table 8                                  .sup.3 same as the footnotes of Table 11                                 

EXAMPLES 33 and 34 Application to 1 Coat Solids

Based on the formulations shown in Table 20, 1 coat solids coating compositions and coating films were manufactured in the same manner as that in Example 16. As shown in Table 21, coating films having excellent appearance and quality, sag limit film thickness and performance of film were obtained.

                  TABLE 20                                                         ______________________________________                                         Unit: part                                                                                        Example                                                                        33 (D)                                                                               34 (D)                                                ______________________________________                                         Polymer non-aqueous particles                                                                       B31     B32                                                                      14.3    14.3                                            Alkyd resin C.sup.1    99.8    99.8                                            Coronate EH.sup.2    33      33                                                Phthalocyanine Blue.sup.3                                                                           15      15                                                Titanium dioxide.sup.4                                                                              15      15                                                Xylene               16      16                                                Butyl acetate         2       2                                                ______________________________________                                          .sup.1˜4 same as the footnotes of Table 10                         

                                      TABLE 21                                     __________________________________________________________________________     Unit: part                                                                     __________________________________________________________________________                            Example                                                                        27     28     29     30                                 __________________________________________________________________________     Coating system         2 coat · 1 bake solids                         Coating color          Red                                                     Form of clear          Clear         Tinted clear                              Coating Base coat      27 (A) 28 (A) 29 (A) 30 (A)                             composition                                                                            Clear coat     27 (B) 28 (B) 29 (C) 30 (C)                             Binder.sup.1                                                                           Base coat                                                                      Polyol resin.sup.2                                                                            A      A      B      B                                                         61     61     61     61                                         Curing agent   Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                              39     39     39     39                                         Polymer particles                                                                             B25    B26    B27    B28                                                       11.1   11.1   11.1   11.1                                       Clear coat                                                                     Polyol resin.sup.2                                                                            A      A      B      B                                                         63     63     63     63                                         Curing agent   Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                                                          Resimene 755                                              37     37     37     37                                         Polymer particles                                                                             B25    B26    B27    B28                                                       5.3    5.3    5.3    5.3                                Appearance of                                                                          20° gloss                                                                              82     83     84     85                                 coating film                                                                           D/I value.sup.3                                                                               90     91     91     92                                 Sag limit film thickness (μm).sup.4                                                                45     44     49     48                                 Film    Water resistance.sup.5                                                                        No abnor-                                                                             No abnor-                                                                             No abnor-                                                                             No abnor-                          performance                                                                            (95° C. × after 4 hours)                                                         mality mality mality mality                                     Adhesion.sup.6 100/100                                                                               100/100                                                                               100/100                                                                               100/100                                    (after water resistance test)                                                  Weatherability.sup.7                                                                          No abnor-                                                                             No abnor-                                                                             No abnor-                                                                             No abnor-                                  (1,500 hours with                                                                             mality mality mality mality                                     sunshine weatherometer)                                                __________________________________________________________________________                            Example                                                                        31     32     33     34                                 __________________________________________________________________________     Coating system         2 coat · 1 bake metallic                                                            1 coat solids                             Coating color          Silver        Blue                                      Form of clear          Clear         --                                        Coating Base coat      31 (A) 32 (A)                                           composition                                                                            Clear coat     31 (B) 32 (B) 33 (D) 34 (D)                             Binder.sup.1                                                                           Base coat                                                                      Polyol resin.sup.2                                                                            A      A      C      C                                                         56     56     65     65                                         Curing agent   Resimene 755                                                                          Resimene 755                                                                          Coronate KH                                                                           Coronate KH                                               44     44     35     35                                         Polymer particles                                                                             B29    B30    B31    B32                                                       25     25     5.3    5.3                                        Clear coat                                                                     Polyol resin.sup.2                                                                            A      A                                                                       61     61                                                       Curing agent   Resimene 755                                                                          Resimene 755                                                            39     39                                                       Polymer particles                                                                             B29    B30                                                                     11.1   11.1                                             Appearance of                                                                          20° gloss                                                                              83     84     82     83                                 coating film                                                                           D/I value.sup.3                                                                               89     90     91     90                                 Sag limit film thickness (μm).sup.4                                                                48     49     52     51                                 Film    Water resistance.sup.5                                                                        No abnor-                                                                             No abnor-                                                                             No abnor-                                                                             No abnor-                          performance                                                                            (95° C. × after 4 hours)                                                         mality mality mality mality                                     Adhesion.sup.6 100/100                                                                               100/100                                                                               100/100                                                                               100/100                                    (after water resistance test)                                                  Weatherability.sup.7                                                                          No abnor-                                                                             No abnor-                                                                             No abnor-                                                                             No abnor-                                  (1,500 hours with                                                                             mality mality mality mality                                     sunshine weatherometer)                                                __________________________________________________________________________      .sup.1 Calculated as solid matter.                                             .sup.2 Polyol resin:                                                           A: acrylic resin A,                                                            B: acrylic resin B, and                                                        C: alkyd resin C.                                                              .sup.3 D/I value: a value representing sharpness of coating films              (determined by Hunterlab Dorigon Model D47R6F Glossmeter).                     .sup.4 Sag limit thickness: a maximal film thickness right before clear        films in Examples 27˜32 and 1 coat films in Examples 33 and 34           started to sag.                                                                .sup.5 No abnormality in water resistance: none of blisters and                discoloration were observed on coating films.                                  .sup.6 Adhesion: 100/100 means no peeling was observed.                        .sup.7 Weatherability: determined in accordance with JIS D 0205 7.6,           Accelerated Weathering Testing Method (with sunshine carbon                    weatherometer).                                                                No abnormality in weatherability: none of cracks and blisters were             observed on coating films.                                               

COMPARATIVE EXAMPLES 1˜4

Based on the formulations shown in Table 22, base coat and tinted clear coatings were manufactured in the same manner as that in Example 7 and 2 coat. 1 bake solids coating films were prepared following the procedure in Example 7. The appearance and property, sag limit film thickness and performance of coating films are all together shown in Table 23.

                                      TABLE 22                                     __________________________________________________________________________     Unit: part                                                                                Comparative Example                                                            1 (A)                                                                              1 (C)                                                                              2 (A)                                                                              2 (C)                                                                              3 (A)                                                                              3 (C)                                                                              4 (A)                                                                              4 (C)                                              Base                                                                               Tinted                                                                             Base                                                                               Tinted                                                                             Base                                                                               Tinted                                                                             Base                                                                               Tinted                                             coat                                                                               clear                                                                              coat                                                                               clear                                                                              coat                                                                               clear                                                                              coat                                                                               clear                                   __________________________________________________________________________     Polymer non-aqueous                                                                       B33 B33 B34 B34 B35 B35 B7  B7                                      dispersion  115.6                                                                              80.9                                                                              50  20  40  20    28.6                                                                             0.6                                     Acrylic resin.sup.1                                                                       --  (B) (B) (B) (B) (B) (B) (B)                                                     32.5                                                                                91.7                                                                             100   78.3                                                                              93.3                                                                                84.5                                                                             108.3                                   Melamine resin.sup.2                                                                      35  35  35  35  35  35  35  35                                      Quinacridone.sup.3                                                                        36  2   36  2   36  2   36  2                                       Red iron oxide.sup.4                                                                       4       4       4       4                                          PTSA solution.sup.5                                                                         1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                                1.5                                                                              1.5                                     Xylene     16  8   16  8   16  8   16  8                                       n-Butyl alcohol                                                                            4  2    4  2    4  2    4  2                                       __________________________________________________________________________      .sup.1˜5 same as the footnotes of Table 8                          

                                      TABLE 23                                     __________________________________________________________________________     Unit: part                                                                                    Comparative Example                                                            1         2         3         4                                 __________________________________________________________________________     Coating system 2 coat · 1 bake solids                                 Coating color  Red                                                             Form of clear  Tinted clear                                                    Coating composition                                                            Base coat      1(A)      2(A)      3(A)      4(A)                              Clear coat     1(C)      2(C)      3(C)      4(C)                              Binder 1)                                                                      Base coat                                                                      Acrylic resin 2)                                                                              Manufacturing                                                                            (B)       Manufacturing                                                                            (B)                                              Example B33                                                                              61        Example B35 + (B)                                                                        61                                               62                  61                                          Resimene 755   38        39        39        39                                Polymer particles                                                                             B33       B34       B35       B7                                               7.8       11.1      11.1      11.1                              Turbid cost                                                                    Acrylic resin 2)                                                                              Manufacturing                                                                            (B)       Manufacturing                                                                            (B)                                              Example B33 + (B)                                                                        63        Example B35 + (B)                                                                        63                                               63                  63                                          Resimene 755   37        37        37        37                                Polymer particles                                                                             B33       B34       B35       B7                                               5.3        5.3       5.3       0.2                              Appearance of coating film                                                     20° gloss                                                                              45        47        18        81                                D/I value 3)   63        65        47        83                                Sag limit film thickness (μm) 4)                                                           43        40        42        32                                Film performance                                                               Water resistance                                                                              Remarkable blisters,                                                                     Remarkable blisters,                                                                               No abonr-                         95° C. × after 4 hours)                                                          gloss decrease and                                                                       gloss decrease and  mality 5)                                        discoloration                                                                            discoloration                                         Adhesion       Base/clear                                                                               Base/clear          100/100 6)                        (after water resistance test)                                                                 detachment                                                                               detachment                                            Weatherability Blisters and cracks                                                                      Blisters and cracks No abnor-                         (sunshine weatherometer)                                                                      appeared, gloss                                                                          appeared, gloss     mality for                                       decreased, after                                                                         decreased, after    1500 hours                                       1000 hours                                                                               1100 hours                                            __________________________________________________________________________      1) Calculated as solid matter.                                                 2) Acrylic resin:                                                              B: acrylic resin B.                                                            Manufacturing Example B33: acrylic resin synthesized in the manufacture o      polymer nonaqueous dispersions.                                                Manufacturing Example B35: auxiliary polymer synthesized for the               modification of particles.                                                     3) D/I value: same as aforenoted.                                              4) Sag limit film thickness: a maximal film thickness right before clear       films started to sag.                                                          5) None of blisters and discoloration were observed on coating films.          6) 100/100 means no peeling was observed.                                      7) Weatherability: determined in accordance with JIS D 0205 7.6,               Accelerated Weathering Testing Method (with sunshine carbon                    weatherometer).                                                                No abnormality in weatherability: none of cracks and blisters were             observed on coating films.                                               

In Comparative Examples 1 and 2 which were based on the process described in U.S. Pat. No. 4,290,932 (gazette of Japanese Patent Application Laid-open No. 56-76,447), surfaces of polymer particles were charged with negative electricity due to fragments of anionic surfactants and polymerization initiators remained thereon so that the polymer particles were adsorbed to quinacridone and red iron oxide charged with positive electricity, resulting in pigment aggregation whereby the appearance and quality of coating films were markedly deteriorated. Additionally, by virtue of the residual anionic surfactants on the polymer particles, appreciable blisters were formed in the water resistance test and also remarkable deterioration of gloss by water permeation into the coating films and discoloration were observed. Further, in the adherence test after the water resistance test, the tinted clear coats were peeled off from the base coats. Additionally, the accelerated weathering test with a sunshine weatherometer also resulted in formation of appreciable blisters and cracks and deterioration of gloss.

In Comparative Example 3 which was based on the gazette of Japanese Patent Application Laid-open No. 53-133,234, the polymer particles had a too small polarity and exhibited poor compatibility with the binder (acrylic resin B), resulting in pigment aggregation whereby the appearance and quality of coating films were markedly deteriorated.

Alternatively, in Comparative Example 4, since the polymer particles were formulated in an amount of less than 1% based on the weight of the binder resin mixture, the sag limit film thickness was no more than 32 μm. 

What is claimed is:
 1. A coating composition comprising100 parts by weight of resinous solid binder component composed of 30˜90% by weight of a polyol resin and 10˜70% by weight of a curing agent to react with hydroxyl groups and 1˜50 parts by weight as polymer particles of a polymer non-aqueous dispersion comprising polymer particles having a total ionic group concentration (I), a hexane tolerance (HT) and a degree of swelling in acetone (S) which are in ranges satisfying the following relations, respectively:

    I<2×10.sup.-5 mol/g particle,

    5<HT<40

and

    S<10;

wherein the polymer non-aqueous dispersion is manufactured by a process comprising the steps of: (1) emulsion polymerizing the following components:(a) an α,β-ethylenically unsaturated monomer containing a hydroxyl group; (b) a polyfunctional α,β-ethylenically unsaturated monomer, and (c) an α,β-ethylenically unsaturated monomer other than the above (a) and (b), by using a water soluble polymerization initiator in a soap-free system or in the presence of a surface active agent containing an ester group; adding an organic solvent to a resultant polymer aqueous dispersion; and then adding a basic compound catalyst or an acidic compound catalyst thereto to hydrolyze completely said surface active agent and water-soluble polymerization initiator at a temperature not exceeding 95° C. as in the condition of suspension; (2) adding an acidic compound or basic compound to said suspension to neutralize said basic compound catalyst or acidic compound catalyst; then after adding a dispersion stabilizing resin, further adding an amine salt of organic acid, followed by leaving a system of said suspension to stand to separate into two layers, an organic layer and a water layer; after removing the water layer, washing the organic layer by adding water; adding an amine salt of an organic acid, followed by standing to separate, and removing the water layer; and (3) removing residual water in the organic layer.
 2. A coating composition as claimed in claim 1, wherein said polyol resin is at least one resin selected from the group consisting of acrylic resins, alkyd resins and polyester resins.
 3. A coating composition as claimed in claim 1, wherein said curing agent is at least one material selected from the group consisting of amino resins and isocyanate compounds. 